a Mini write up to follow...
Well , the expected turnaround time on this was 4 to 6 weeks , not because I'm lazy but everything has to be made as a one off to suit, and in this case I actually did the conversion twice
1st setup was completed in 5 weeks, but the intake temps were higher than I wanted, especially given the intecooler size and known efficiency, the answer was go for a larger compressor unit , this would boost the same, but with more spare capacity and not force the IAT up as high.
I sourced a revised turbocharger to suit, downside was I had to repackage the whole setup due to the physical size increase, the original top mounted turbo manifold was scrapped and replaced with the bottom mount you can see in the pic above, the long exit branch is there to provide a smooth collector for all the gasses from the 4 into 1 log section, then carry this flow down to the turbo inlet port.
The revisions meant I had to replumb the intercooler and oil feed areas to suit, but the new package was far neater and compact as a result, if a little stealth in that unless you know where to look, there's no evidence of it being there.
ChrisP's car HAD to retain its CAT which was a limiting fator, I used 2'5" stainless to make the complete downpipe and system, and placed a 200 cell stainless cat downstream of the turbo , an emissions test revealed the following figures.....
CO2 ( max 0.30%) 0.01
HC ppm ( max 200) 30ppm
Lambda (0.97-1.03 max) 1.03
I used smaller injectors than I'd have liked because the limits are so stringenet, there's enough flow there now for 200HP , no more as resoloution is limited by minimum injector opening times.
now the emissions are not the most exciting part of the swop, reaching those targets is not easy, a lot of mapping of the main tables, and the 02 driven correction has resulted in emisssions that are lower than stock
To protect the cat, the car is mapped to run stoich through the rev range until boost goes over 110 kpa, there are also trim maps triggered by the tps to give a richer mixture for accel/overtake, we push from 14.5:1 afr to 12.1 on heavy accel, almost like a carb pump jet if you remember those.
My brief was to bias the conversion for torque, the M40B18 is not the guntiest engine in the world, and in the heavier cab its less of a fireball than usual, so this is where my efforts were concentrated.
Rether than use the turbo to pump a head of boost pressure into the engine, were using it to push the VE up to 100% everywhere, with small head of boost over and above atmosperic.
the end result is almost zero lag( unless you're in a too high gear) and instant go when you need it.
Drives great, sounds great, uses little or no fuel when driven hard, runs same temps as stock too, always a bonus.
If and when Chris decides he'd like more power and torque, the ECU and turbo will have plently in reserve, however the torque will move up the rev range at the expense of higher bhp figures.
TBH I drove it for 3 days never wnating more, the delivery and economy are spot on and suit the characteristics of the cab perfectly.
Arse dyno would put the torque on par with a 2.7 and the HP around the M20B25 level, all that and 30mpg too.
soory to bore/technobabble you all, but this is good onfo
