97 40th Turbo Build

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:beer:
One question before getting the grill fired up... Do I really need an A/F Ratio gauge?

IMHO, not really. If you're considering a wideband setup like the Innovate LM-1, then I say go for it. Otherwise, I don't see the point in a narrowband gauge, as it doesn't really help you when tuning.

If I should use an A/F ratio gauge can I weld in a seperate O2 sensor and wire it without hacking into the factory harness?

Absolutely. Weld an O2 bung in the downpipe about 6" from the turbine outlet and you're good to go. :beer:
 
Cangrats, now you will know what the turbo hype is about. I would go wideband all the way. AEM or similar. The A/F into the stock system is pretty much useless. That wideband will be worth every dollar. Will allow you to back out quick enough if you need to and will be invaluable in tuning and monitoring.
 
way to go. and such a clean install.

my truck doesn't seem to lean out on the narrow band. so if less than 6psi you probably dont need it. but the narrow band is easy to install and is certainly usefull. for example:

most of the time the N band just bounces back and forth between yellow and red reflecting the how the motor constantly adjusts fuel delivery in closed loop. when you smash the gas the green light stays on for a few momments as the motor is running closed loop. all this is of little use

But when I am climbing the grapevine here in cali I will often have the booste stable at 4-6lbsm as I climb so as to prove something (as my wife reminds me). My turbo set up will creep at high enough loads and rpms-about 4800 rpms. (the wastgate cant divert exhaust gasses enough so boost cant be controlled ands booste will start to rise) I have not pushed the envelope hard enough to know where the limits of my fuel delivery lie but there is no doubt in my mind that I could easily lean my motor out at 5000rpms on a steep grade or in the sand if pushed hard enough.

The narrow band lets you know if this is happening. if it is in a lean situation the gauge will show a constant red light. the jnarrow gauge is good only for this situation. when I climb a grade I am watching 4 things:
1.egt
2.booste
3.the red light on narrow band
4. water temp (not the oe gauge)
 
there is no doubt in my mind that I could easily lean my motor out at 5000rpms on a steep grade or in the sand if pushed hard enough.

This flies right in the face of everything I've read so far. Christo posted a dyno chart that had rich condition at WOT, TurboCruiser and a couple of SC'd truck also had the same thing.

As of right now I have no plans on installing a A/F gauge. I'll let the ECM take care of it.
 
95% finished.... I still have to heat shield the turbo, finish installing the gauges and have a shop complete the 3" exhaust.... Oh, and put the hood back on....
Turbo 1.webp
Turbo 2.webp
 
Shameless poser pic...
Flexing Pics 030.webp
 
95% finished.... I still have to heat shield the turbo, finish installing the gauges and have a shop complete the 3" exhaust.... Oh, and put the hood back on.... take it in for a dyno

Fixed it for ya.

-B-
 
Rick, let me know what day and what time and I will be there. I'll PM you the address.... It would be nice to swap ideas.
 
This flies right in the face of everything I've read so far. Christo posted a dyno chart that had rich condition at WOT, TurboCruiser and a couple of SC'd truck also had the same thing.

As of right now I have no plans on installing a A/F gauge. I'll let the ECM take care of it.

Rick, that was a 93 truck with a supercharger, rising rate regulator and flapper style air flow metering. Not the turbo. I know with AVO's turbo we can make the truck lean out at 7psi of boost. a $300 wideband is cheaper than a 5k motor. I would also take it to a dyno and monitor the wideband O2 under different loads. The most dangerous is high boost lugging the motor. WOT is normally not an issue, but climbing a grade at 1/2 throttle under boost. You spent all this time building this, don't skip the last part. I can show you a block from a truck that was fitted with a Safari turbo and made it 1/2 way to Moab.
 
Rick, that was a 93 truck with a supercharger, rising rate regulator and flapper style air flow metering. Not the turbo. I know with AVO's turbo we can make the truck lean out at 7psi of boost. a $300 wideband is cheaper than a 5k motor. I would also take it to a dyno and monitor the wideband O2 under different loads. The most dangerous is high boost lugging the motor. WOT is normally not an issue, but climbing a grade at 1/2 throttle under boost. You spent all this time building this, don't skip the last part. I can show you a block from a truck that was fitted with a Safari turbo and made it 1/2 way to Moab.

As far as I know the AVO system runs in open loop. If the sytem in running in open loop then you should have someway to monitor the engine as the ECM isn't. So far TurboCruiser has been in closed loop up into the 36 lb range with my MAF and that's all I'm interested in. In closed loop the ECM is fully aware of what's going on and monitoring and adjusting the system.

If it's different on my truck then I'll have to rethink my decision, but for now I'm not worried about my fuel management.
 
As far as I know the AVO system runs in open loop. If the sytem in running in open loop then you should have someway to monitor the engine as the ECM isn't. So far TurboCruiser has been in closed loop up into the 36 lb range with my MAF and that's all I'm interested in. In closed loop the ECM is fully aware of what's going on and monitoring and adjusting the system.

Agreed, but he can not be running in closed loop all the time. I have to go back and read the thread on the the new MAF sensor. I understand what happens in closed loop, but I want to know what the truck is doing in open loop.

Also, the AVO is more volume of air than the Safari. We have had Safari systems up to 12 lbs of air on stock fuel system and it would not go lean. AVO starts doing it at 6 lbs of pressure.

If it's different on my truck then I'll have to rethink my decision, but for now I'm not worried about my fuel management.

Maybe on the size turbo it doesn't matter, but I would still put a wideband O2 on it since that is really your only feedback.
 
the thing to understand Christo is the stock MAF gets saturated at around 26lbs. So air volume higher than that is not seen by the ECM. So whether it's 26 lbs or 36lbs the ECM sees the same value for air flow. This is what's sending the ECM into open loop. It is now flying blind and using the TPS and RPMs to adjust fuel. Because the ECM no longer sees air flow you can get into situations where lean conditions can be devastating.

To this point TurboCruiser has pushed his truck up to having the MAF read 36.6 lbs of air. So with my MAF the ECM is still managing the fuel delivery based on the MAF input.

At some point even my MAF with get saturated and stop responding but we haven't hit that point yet.

I fully intend to stay below the saturation point so the ECM will monitor and deliver fuel as designed.
 
the thing to understand Christo is the stock MAF gets saturated at around 26lbs. So air volume higher than that is not seen by the ECM. So whether it's 26 lbs or 36lbs the ECM sees the same value for air flow. This is what's sending the ECM into open loop. It is now flying blind and using the TPS and RPMs to adjust fuel. Because the ECM no longer sees air flow you can get into situations where lean conditions can be devastating.

To this point TurboCruiser has pushed his truck up to having the MAF read 36.6 lbs of air. So with my MAF the ECM is still managing the fuel delivery based on the MAF input.

At some point even my MAF with get saturated and stop responding but we haven't hit that point yet.

I fully intend to stay below the saturation point so the ECM will monitor and deliver fuel as designed.


I understand all that, however if 24 lbs of air was the max the ECU could see with the stock MAF, then does it know how to handle 36 lbs if air? IE, does the fuel maps go that high? I understand that he is seeing that and also the OBDII reports it is in closed loop.

It is not just MAF input that puts the ECU in open loop. There is RPM and TPS as well. You can go into open loop before you reach saturation on the MAF. I am not disputing that the MAF is not working, I am just pointing out that it is foolish to put such a drastic mod on a forced induction truck and not monitor with a wideband O2. You can not solely rely that you will be in closed loop all the time.

He reports better fuel mileage. Is that because his truck is running more effecient in closed loop, or is that because he is running lean in open loop? I Exactly your trust in the O2 feedback system is why I advocate the wideband. Since the 02 sensor feedback is ignored in open loop, the drive should monitor it. For normally aspirated vehicles, there is no issue since the fuelmaps at open loop was done by Toyota and set up pretty conservative. However when you do forced induction that is all out the window.

I just don't understand why there is such a resistance to monitoring what is going on. Reading the OBDII data is not enough.

Next 80 we do with a AVO I am going to try your MAF because I can see the benefits, but I will simply not just rely on the trucks feedback.

If trubocruiser buys the wideband, we can help him install it and do some monitoring.
 
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If trubocruiser buys the wideband, we can help him install it and do some monitoring.

I should have set this up a long time ago. I want to replace my AutoMeter narrow band with a AutoMeter wideband. Talked to Christo about this along time ago even prior to the Modded MAF. I've been hovering here at a plateau of power where I always assumed I needed more boost to get more power. But to safely push more boost, I needed much more data via something to insure that I can compensate if it leans out. I think this fact is well established.

With Rick's MAF I've got more "resolution" - if you think of it like data and more "range" - also if you think of it like data. BUUUUT, my narrow band A/F gauge and my "narrow band" O2 sensors, and my "narrow band" (insert older technology of choice) cannot necessarily react quickly enough. I would however think that a knock sensor could, can someone confirm or deny that for me please?

Now what I would ask is if all my readings indicate a slightly rich condition not just at WOT but throughout the range of pushing the thing, is that a safe indicator or is it really no indicator at all? I guess I would think that it is a good indicator that I'm in closed loop much more of the time (not all the time but even at open loop now the open loop is modified where many of the sensors are still reading - prior to this mod when I was in open loop it was realllly open loop and almost everything read ZERO's!) and that at any range of either WOT or getting to there quickly the rig stills seems to tend towards rich (as it always did) but it is not stinkin saturated rich like it always was at WOT. I think that my management is more efficient 99% of the time and I think that most would agree with that. What I'm trying to reconcile is risk associated with that 1% of pushing the thing. I think what Christo is saying is simply that the 1% can represent risk and that to monitor that the wideband is better. I agree. I think waht Rick is saying is that the data directs us to see the situation as almost always more accurately calibrated, and that at those rare times of open operation, still somewhat rich. I agree there as well.

I'm loving this by the way so please let the experts resume, I just wanted to add the above. Tahnks. :cheers:
 
i'm actually following this thread believe it or not...i mean, kinda understanding what you are talking about.

Hopefully we will have this all hashed out by the time i win the lottery and turbo my rig.
 
Ok, so here is my problem with the wideband. Who is going to be watching the wideband while at WOT and high rpm? Your eyes will/should be on the road and other cars. By the time you notice the wideband reading lean you are in bad shape and running a high chance of engine damage.

Rick solved the fuel managment issues by allowing the ecu/system to do the fuel rich/lean calculations/corrections correctly not the driver. There have been many many cars with forced induction and narrow band o2 sensors including 80's.

BTW, when I reviewed turbocruisers datalogs early on the sensors were all reading in proper range. ie timing advance, O2 sensor, ect. The stock ECU can handle 33 lbs of air per min. fine in the logs I have reviewed. Turbocruiser maybe you could share those logs?

In other toyota applications (maybe cruiser too) when the sensors are too far out of range the ecu respones by cutting all of the fuel not just a portion. Nice safety.

Christo, so what turbo is the AVO system using that outflows at 6 psi than the safari turbo at 12 psi.

"I can show you a block from a truck that was fitted with a Safari turbo and made it 1/2 way to Moab."

That is kinda like yelling fire in a theater... Give more data than a dead block... What part and or parts failed that lead to the engines death.
 
Ok, so here is my problem with the wideband. Who is going to be watching the wideband while at WOT and high rpm? Your eyes will/should be on the road and other cars. By the time you notice the wideband reading lean you are in bad shape and running a high chance of engine damage.

This gauge is as easy to read as any out there, including stock gauges. http://www.aempower.com/ViewCategory.aspx?CategoryID=70 The damage does not always happen at WOT (Remember WOT is something like 75% throttle) and higher RPM.

Rick solved the fuel managment issues by allowing the ecu/system to do the fuel rich/lean calculations/corrections correctly not the driver. There have been many many cars with forced induction and narrow band o2 sensors including 80's.

I am not saying it will not work or that it does not work at closed loop. All I am saying is why are you guys so reluctant to monitor the truck?


BTW, when I reviewed turbocruisers datalogs early on the sensors were all reading in proper range. ie timing advance, O2 sensor, ect. The stock ECU can handle 33 lbs of air per min. fine in the logs I have reviewed. Turbocruiser maybe you could share those logs?

It reports 33 lbs of air, but do you know where the fuel map ends?

In other toyota applications (maybe cruiser too) when the sensors are too far out of range the ecu respones by cutting all of the fuel not just a portion. Nice safety.

I do not see the relevance of this. If your truck is going lean in open loop it will detonate (you won't hear it) and the pistons will be melted way before the ECU figured out something is wrong.

Christo, so what turbo is the AVO system using that outflows at 6 psi than the safari turbo at 12 psi.

I will have to dig up the number again. This is just from experience. 97 truck with stock MAF and if we do not add fuel in certain cases, the truck goes lean. Confirmed on dyno with wideband O2 and driving with wideband O2.

"I can show you a block from a truck that was fitted with a Safari turbo and made it 1/2 way to Moab."

That is kinda like yelling fire in a theater... Give more data than a dead block... What part and or parts failed that lead to the engines death.

Melted a piston and eventually blew the headgasket. This happened in about 100 yards doing 80/90 mph on the way to Moab. This was not a customers truck, it was a friend that brought a Safari turbo back from Australia. Thought the truck was tuned properly and it was not.

Again, other that the gauge reading issue, which I think is not an issue, why not use one? The wideband is more accurate over a wider range and reads the fuel mixture back to you. You can immediately see what is going on. The o2 sensors function is to get the truck to run as close to 14.7 as possible when in closed loop. It does that fine, but playing with turbo's and MAF mods changes the fuel mixture. You should keep an eye on it. The conventional O2 sensors will read .45v at 14.7 fuel ratio, however as soon as it changes from there, they saturate. In closed loop the fuel trim takes care of this and always want to get the truck back to that spot. However when you are in open loop, you have no idea what is happening to the fuel mixture, other than grossly lean or grossly rich. Are you running at 11, 10, 15 or what. Very important. I would suggest you use your logging software and set it to record open loop and closed loop flags and then record a run. Play it back and see how many times you are in open loop. If this is only at idle that good, but from my experience it is not. Rick's MAF might affect that, but I bet you will still have cases where you are not.

I do not have a wideband O2 on my 100 series (no convenient spot for the gauge) but we did all the tuning with one over hundreds of miles. I am pretty sure it never goes lean. We also confirmed that with a lot of dyno runs.

This is a good read on the subject. http://www.forparts.com/BoswidebandO2.htm
 
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