Builds Engr 88 Pickup - 22RE Megasquirt turbo build (1 Viewer)

[EngEngr]

Back from our 4000 mile road trip and 8 national parks in the 80 series.

Truck is going back in for turbo install. NA calibration is running great.


To do this winter:

Exhaust manifold and down pipe
Intercooler piping
Intercooler mount
Radiator standoff and electric fan wiring
Turbo intake
Crankcase vent
Oil supply/return line
Transfer case rebuild - leaks and loose output shaft

 

[EngEngr]

Starter tried to set me on fire. Replaced with OEM Denso reman 1.4kW and 1/0 cable. Cranks at 900rpm now

 

[EngEngr]

So the starter was actually fighting against hydrolock!

Another setback.

Megasquirt injector driver failed and flooded cylinder 4 with fuel.

Going to limp it into the garage on 3 cylinders and then start the winter project of turbo and MS2 repair.

Hopefully the head gasket is alright

0.4 ohms and continuity between injector driver C output and chassis ground when the MS2 is powered by 12V

 

[EngEngr]

Figured out that the MS2 board was fine.

Driver C is not only connected to pin 18 out of the option port, but also connected to the ECU connector for the cold start injector. I had cut the connector off and taped the ends but it must be shorted to ground. I was also able to rewire the fuel pump correctly so now MS can actually turn the pump on/off instead of always being on. Pin 1 to Pin5 from the AFM, mine was green and blue/red.

Pulled Injector bank A,B,C pins out of the factory connectors to avoid shorting any other cylinders and it fired up. My VE table was WAY off (25-30%) and I'm pretty sure that cyl 4 has been stuck on since installing the 550s but now does it sure run smooth. Wideband is less noisy. I can actually run leaner than 13.00 and it doesn't randomly misfire.

I was also playing around with idle timing and recorded a data log sweeping timing from 12deg up to 40 deg. I think as expected, engine RPM increased as I held AFR and increased timing. I found that the engine RPM stopped increasing around 34deg and consider this maximum brake torque timing for idle. I set my idle timing to 28 deg and its been running pretty good.

 

[aztoyman]

WAY over my head but I'm enjoying this thread.

 

[EngEngr]

Cold start calibration season!
Started with a base equation and have been slowly adding 1ms pulse width and increasing start speed. Goal is to get it below 1sec.

The Clausius-Clapeyron phase equilibrium equation can be used to calculate how much liquid fuel you need to inject to get the same amount of fuel vapor vs temperature when you have a known good starting temp (175F used in my calcs, 2.1ms of fuel).
Base curve ends up looking like this....

In Excel
100 * EXP(400/0.273*(1/T2-1/352.44)))
400 is the latent heat of vaporization of gasoline in kj/kg
0.273 is the ideal gas constant in kj/kg
T2 will be your start temperature curve in kelvin ( =Convert(A1,"F","K") )
352.44 is your hot start temp in kelvin (175F in my example)

Start Temp F	% Fuel Increase
-40​	841​
-20​	632​
0​	486​
25​	362​
50​	277​
75​	218​
100​	175​
125​	143​
150​	119​
175​	100​

I also set my prime pulse to be equal to the cranking PW to give the ports 1 shot of cranking fuel.

Prime pulse = Cranking fuel % x 175F pulse with (2.1ms in my case) / 100.


Current VE table when all injectors work.

Timing without boost

Prime, crank, after start enrichment, after start taper, warm up enrichment

 

[EngEngr]

Here we go

 

[EngEngr]

Mocking up cooling package depth. Looks like my intercooler + 3 row radiator + spal slim fan will fit.

Goal is to keep AC while minimizing pipe length. Sacrificing slightly warmer MAT temps by mounting behind the AC condenser but significantly less pipe length and pressure drop

 

[EngEngr]

Studs and spacers for mounting the radiator and intercooler.

Cast 90deg elbows in the mail

 

[EngEngr]

Turbo located and starting to fit up pipe

 

[EngEngr]

 

[EngEngr]

Was a good day. Tacked up to figure out where I need to drill through for port 2-3.

For a first attempt at pipe fitting I'm happy with what it turned out to be.

 

[aztoyman]

Nice job. Very stout and clean looking flanges.

 

[EngEngr]

Punched through with a 1-3/8 hole saw. Starting final welds.

Tig is hard.

 

[EngEngr]

Turbo flange warped 1/16 inch woops.

Manifold in done. Tubing ordered for downpipe and intercooler

 

[EngEngr]

Cut 2 inches out of the heater core pipe to clear the downpipe

 

[EngEngr]

Small update. Starting downpipe and waiting for Send Cut Send to ship my fan shroud

2.5" downpipe mock up

 

[EngEngr]

Shout out to the UPS drivers for delivering in an Iowa blizzard.

1/8th aluminum sheet with m6 flush studs for spal 16" fan

 

[EngEngr]

Down pipe is tacked up. Starting to lay out intercooler piping.

 

[EngEngr]

Cast aluminum intercooler elbows and looking at piping layout. Looking like my plan is coming together