Because Build Threads Are A Thing

[Fstrnyou]

I fear this is my biggest concern.
Contact with master cylinder. @JBR;

Also a housing comparison pic...for shits-n-giggles.

[Fstrnyou]

Upon further investigation, the intake is only lightly rubing the master cyl. I think I may be able to shorten the BPV hose slightly to "pull" the intake forward a little.

Other things with pics:
Trimmed the battery tray modified it to hold a 51r.
Removed a harness bracket.
Also had to remove this plastic harness cover thing, so I reloomed it.

[Fstrnyou]

Here goes nuthin.

[Fstrnyou]

About 5 months ago...

Originally Posted by Fstrnyou The turbo upgrade is listed almost dead last. It could be 2 years, maybe longer, before I take that step. Until then, I'm fairly limited to 280-300whp. At some point before I'm ready for that step, I should have...at the very least...started building the back-up motor.

Insert foot in mouth, eat my hat, and facepalm.

inbeforeyougonnablowyourshitup
inbeforeitoldyouso

[Fstrnyou]

New desk art for work.

Busy this weekend, so I'll be tuning in 2 weeks.

[Fstrnyou]

Install day tomorrow. Been running a 'post install' tune for a few days now to make sure it's all kosher so, if there's an issue, I can rule out the tune as the culprit. 10psi with a lot of timing pulled is.....boring! Puppy should start off at 15, so I'll still need to be slightly cautious for the first few part throttle pulls and gradually work up to spring pressure.

0% WGDC
0% Increase Comp
rfinkle's base timing map, with an extra degree pulled, above 1.1 load and 3k. 2.5k column interpolated over to 2k column above 1.1 load (all tables except MAX, +2 degrees there)
Throttle tables now have max 70% instead of 80
OL/CL Transition 15/20/20, 100% throttle, 1.1 load (all tables)
AFR target 11.5 above 1.1 load. (all tables except knock, targeting 11.0 there)
I left my load targets alone since I'm almost certain running spring pressure won't reach it. (2.05 and 18psi on K04). If it does, my load cut is 2.2.

I think this will put me at a safe place to start.

I'll have a laugh tomorrow. My buddy was giving me crap about daily spraying PB on any exhaust fastener I could find. So I stopped spraying last week. It'll be funny watching him struggle and me saying, I Told You So! And if it comes apart easy, I'll just say it's because I sprayed it for a few days. I still win.

Thanks again to @davychronic; for the downpipe.

[davychronic]

Looks good, thats a fun turbo all the way up to 30psi

[Fstrnyou]

I wanted to install both OCC's tomorrow too, but SOMEONE, who shall not be named, has them on backorder. Business must be good, so not hatin about that. I didn't want that valve cover vent crap going thru this nice piece of @CorkSport; art.

[Fstrnyou]

Coming along. Only put about 3 hrs into it yesterday. Heat shields removed without much fuss. O2 sensor was the biggest bitch,. O2 socket on a breaker bar didnt do shit. Put the O2 socket on a 1/2 drive impact and 1 quick tap was all it took to wrap tge O2 harness arpund the socket about 3 times. Easy peasy, harness appears to be undamaged. DP studs came out without too much effort. Now I'm just trying to figure out how that upper DP is supposed to slide out. The heat shields are still on the cat, so maybe it'll be quite a bit smaller once those are off. I'll at least try discon necting the RMM and PMM to shift the engine forward, but it doesn't look like it will get me much.

Adding puctures, I realized I lied about the heat shield bolts. 1 of them rounded off the head. But a few minutes with an air chisel to try and cut the bolt head off ended up weakening the mounting tab enough for it to break offinstead. Winning!

[Fstrnyou]

Took about an hour to get the shields off the cat and the DP removed. The past 3 hours has been a struggle. Getting the oil drain line disconnected... I ended up leaving it on the block and disconnecting from the turbo. Oil feed banjo, no big deal. Loosened the turbo from the manifold and moved it far enough to reach the engine-side coolant banjo. Removed that line entirely down to the xfer case cooler. Fought and fought trying to squeeze this hair dryer out the intake side per the instruction and finally gave up. Off came the manifold. Few minutes later, the K04 is on the bench. Why dosent everyone do it this way? Note to those that try it this way: the oil supply line is attached to the head flange (8mm socket I think), so unbolt that before you go yanking on the manifold trying to get it out.

Lunch break.

[Fstrnyou]

Just prior to said 4hr long lunch break, I went to reinstall the coolant drain in the radiator. It felt oddly loose when I removed it, so i was going to make it a little tighter going in. Mistake! Head snapped right off. Drove all over town looking for another one. Autozone next town over had one. Get back to put it in...too small. FML!!! So my buddy is like, "Fuck this shit. I'll make one." He has a lathe and happen to have some nylon bar stock laying around.
So off he went while I kept wrenching. Worked like a charm. (FWIW: it's an M12x1.25. A short bolt would have worked too)

Anyways, enough of that. Got it all mostly back together. Just a little bit of buttoning up left.

[dagrimey1]

The peacock from a universal Toyota part at your local parts store will fit.

Sent from my XT1575 using Tapatalk

[Fstrnyou]

Originally Posted by dagrimey1 The peacock from a universal Toyota part at your local parts store will fit.

Well, it's handled now with the nylon piece.


Car seems to be running fine for the most part. I was told the wastegate spring pressure is/was 15psi, but it would hit 10 then slowly taper UP to 12 or so by redline with 0% WGDC.

Hearing a strange noise that I think is an exhaust leak between the turbo and manifold. Hard to say. It isn't audible until I'm well into boost. I don't think it's a boost leak because I'm hitting AFR targets @ WOT and so far my fuel trims are good.

A pull this morning put me at ~16psi with 60 degree ambient temps. Wastegate is having to do a lot of back and forth to hunt load targets (1.9). Logged WGDC graph looks saw toothed. It's over-correcting both ways and boost oscillates between 15.5 and 16.5. Last night was in the lower 70's. Same tune was hitting ~16.5psi with the same 0.5psi swing in either direction. K04 would oscillate too, but it was much tighter and smooth, within +/- 0.2 psi.

No complaints really. I wasn't expecting to drop in a completely different turbo and have it run flawlessly. I'm only doing 3rd gear pulls now to get in the ball park while not overly speeding. Once I like where it is, I'll do a few 4th gear pulls and make the minor adjustment as needed.

[Fstrnyou]

I'm not a fan of turbo lag. Read many times that it spools pretty quick or this is the turbo Mazda should have installed OE or nearly stock spool (as the Corksport white paper put it). Corksport claims 20psi by 3200 with catted DP, stage 2 intake, and CS TMIC. I'm catless with a 3.5 intake and only hitting about 12 psi by 3200. I wouldn't think a TMIC upgrade would do anything for spoolup given the stock unit isn't restrictive at such a low volume. Nor would I think a suspected small exhaust leak could cut it down that much. I understand a small exhaust leak is no different than a leaking wastegate. Just don't /didn't think it would make such a huge impact.

FWIW, I'm ordering new manifold & turbo gaskets this evening. Gotta get that fixed right away. Need to take it easy until that's solved. I'll deal with spoolup later.

[Omega]

The stock unit has a HUGE pressure drop compared to aftermarkets at least 3psi more - it's great at cooling, terrible at causing the turbo to work harder.

[Fstrnyou]

Originally Posted by Omega The stock unit has a HUGE pressure drop compared to aftermarkets at least 3psi more - it's great at cooling, terrible at causing the turbo to work harder.

Now that the turbo is done, aside from having to fix an exh leak, I'm now budgeting for W2A intercooling.

[Omega]

Yeah your exhaust leak is probably causing your spool issues. Turbos spool with exhaust energy, energy lost = slower spool/less power. It's also letting heat escape which turns into the same problem. When you're all set hardware wise post up vdynos along the way

[Fstrnyou]

Originally Posted by Omega When you're all set hardware wise post up vdynos along the way

I have a before/after Vdyno comparison, but it's not quite apples to apples. I have a ghetto pic attached below.

K04 in Red. Several blips of .35, .70, and 1.05 KR which explains the AFR below 11:1. 46 degree ambient temps.
Blue line obviously would have to be the Corksport turbo. 80F ambient temps.
Both tunes have similar boost and timing.
The plots ARE corrected for temperature.
Ignore that crap below 3k. I was playing with running K04 spring pressure in the low revs.

[Mazdazilla6]

Your slow spool is more likely than not your wastegate actuator. If you're not seeing 15 psi at 0% DC then your actuator is not at 15psi. Adjust that up a bit more to 16-17.

[Omega]

@Fstrnyou; I meant post up your CS turbo logs vs final K04 logs after everything is sorted and final tune is done - or keep posting each iteration

Edit: Also just realized that's the base map -- NICE definitely keep posting up more logs.

[Fstrnyou]

Originally Posted by Omega @Fstrnyou; I meant post up your CS turbo logs vs final K04 logs after everything is sorted and final tune.

I'll edit that previous post with a "better" apples-apples instead of posting a new VDYNO comparison. The only issue being the ambient temperature difference, 46 for the K04 and 80 degrees for the Corksport pull.

Added 2 more degrees since then, but I haven't run the most recent revision at my Vdyno spot yet. Per your "hint", I won't post every iteration.

I know I said I was going to take it easy with that exh leak, but I cant help myself. Still waiting on gaskets to arrive. Shame on me.

[dagrimey1]

I've got an extra exhaust gasket if you want to use it till other arrives and just swap with me. OEM never used 2 on hand.

Sent from my XT1575 using Tapatalk

[Fstrnyou]

Originally Posted by dagrimey1 I've got an extra exhaust gasket if you want to use it till other arrives and just swap with me. OEM never used 2 on hand. Sent from my XT1575 using Tapatalk

Thanks, but I have my daughter this weekend so I wouldn't be able to get to it until Monday. They shipped out Wed, so I should have them by then.

[dagrimey1]

Aren't you going to the Dragon meet? When you leaving, PM me info maybe we can ride up together

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[Fstrnyou]

Originally Posted by dagrimey1 I've got an extra exhaust gasket if you want to use it till other arrives and just swap with me. OEM never used 2 on hand.

I spoke too soon. Just got a email earlier saying the gaskets just shipped today with expected delivery of the 27th. That just won't work. I'll be needing both manifold gaskets. The turbo/manifold gasket I know for sure is leaking. I'd like to replace the engine/manifold gasket since I reused my old one. Not sure that was such a good idea, but desperate times call for desperate measures.

Originally Posted by dagrimey1 Aren't you going to the Dragon meet? When you leaving, PM me info maybe we can ride up together

I'm heading up Thurs evening after work. A buddy of mine might ride with me if he has nothing else to do that weekend, so it's not a sure thing. I told him to bring his Honduh, but he doesn't want to take it that far from home. LOL

[Fstrnyou]

Originally Posted by Fstrnyou I'm heading up Thurs evening after work.

Correction: took 1/2 day Thursday. Maybe you, @dagrimey1;, have time to swing by and help throw those gaskets on before a road trip...if they're delivered soon enough.

[dagrimey1]

I'll be gone early on Thursday as I plan the Day dinner so I need to go and get things started. Most of the Charlotte crew I know is leaving around lunch time or so. I will let you know if things change.

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[Fstrnyou]

Originally Posted by Mazdazilla6 Your slow spool is more likely than not your wastegate actuator. If you're not seeing 15 psi at 0% DC then your actuator is not at 15psi. Adjust that up a bit more to 16-17.

Replaced leaky turbo gasket. Helped with spool slightly. Replaced it the same night I got home from ENM.
Adjusted in more preload last night, more this morning, then more before my way home from work today. Looks to be set pretty good at 15psi but still spools slowish. Oh well. I shouldn't be logging from 2k anyways. Just disappointed it doesn't spool as quickly as advertised. But while on the Dragon and Skyway, revving the snot out of it, it spools plenty quick.
I've since cranked the stock EBCS back up. ~23% DC gets me to 18psi, but it was spiking into the 19's, so I cut the WGDC INCREASE down from 10% to 5%. The ECU is trying to ramp up boost, but once it's there, it doesn't drop DC quick enough and overshoots. In a 3rd gear pull, it spiked to 20.2. I may even set the INCREASE to 0. IDK.

[Mazdazilla6]

Sounds like you need to work on the PID tables for WGDC. You should be able to have it spooled by 3k ish. Honestly though I'm not sure why you'd want it spooled earlier than where you're at on a stock bottom end.

[Fstrnyou]

Originally Posted by Mazdazilla6 Sounds like you need to work on the PID tables for WGDC. You should be able to have it spooled by 3k ish. Honestly though I'm not sure why you'd want it spooled earlier than where you're at on a stock bottom end.

I did say I should NOT be starting my logs that low, but the fact remains. Everyone, even Corksport, says I SHOULD/COULD be full spool by 3k. But I'm not. With WG spring adjusted to hold 15 and stating the log at 2k or so, I'm only up to about 11psi by 3k. Not even remotely close to the claimed 20psi in the White Paper.

My gripe is that it spools slow, not that I can't hit 20 by 3k.

With WGDC and loads bumped back up now, I'm aiming for 18-19psi. I don't reach those targets until after 3500. As to be expected, increasing WGDC did nothing to increase spool rate below spring pressure.

[Fstrnyou]

Originally Posted by Fstrnyou My gripe is that it spools slow

In the comparison attached, the K04 flattens out early because my 2500 and 3k load targets were lowered to below stock levels. Otherwise, the boost would have kept going up to stock levels right away instead of at 3500.

Both logs were done in 4th gear.
Even starting the pull at a lower RPM, it's clear the Corksport turbo is slow to build.

My car vs White Paper test vehicle, I'm Corksport catless and have a 3.5" intake working in my favor, but I still have the stock TMIC. And I stand corrected, it's 20psi by 3200.

[Fstrnyou]

During EMN, I received several comments regarding blue smoke / burning oil. A car buddy of mine also commented this past week and said it was much worse than he remembers seeing previously.

Compression and Leak-Down check will be happening this week, but even if those come back positive, it's not a definitive "OKAY to proceed" result. So...I'll be rollin easy until I have a back up plan which begins with fixing my old car and ends with having another engine ready.

Final logs below from tonight will be the last for a while. Planned on running it up to 20psi on the stock MAP sensor, but oh well. To be continued...

[Fstrnyou]

Still running decently. No tune changes yet aside from installing 3bar map about a month or so ago.

Installed DM Stage 2 OCC a few weeks back. I have an eBay can on standby for stage 1. Might do it July 4th.

[Fstrnyou]

The eBay OCC did go in at the stage 1 location.

The Journey to Liquid-to-Air Intercooling
--Phase 1: relocate battery
----Step 1: aquire that HTP bracket (done)

[Fstrnyou]

Mixed update...
Received more battery relocation parts. Just need to fab up a try and bolt it in.

Sad news...it seems my TOB or clutch took a shit. Lite clutch feel and heavy vibration in the clutch pedal plus it's difficult to shift. Managed to get it home. My parts getter Tacoma just got promoted to DD.

[Fstrnyou]

Build Thread Tangent...

Here I go for a weekend of wrenching.
1: Clutch Swap
2: VVT Replace
3: All front Axle Seals (trans & xfer case)
4: Shifter Pivot Seal
5: Maybe even a few Russian bushings too.

[Fstrnyou]

Shit break!

2.5 hrs in and almost done on the top side. Still have to drain coolant, lay PS pump to the side, and disconnect DP from turbo.

Yes, I'm pulling the motor out instead of dropping the subframe.

[Fstrnyou]

Calling it a night.
Doesn't seem like much happened the past 4hrs. All items listed in previous happened, plus xfer case & trans drained, RMM and driveshaft disconnected.

Tomorrow morning:
Need to lay A/C compressor to the side then start working on getting axles pulled.

[Fstrnyou]

And she's out.

[Fstrnyou]

For a while now, I've had issues with a weak clutch pedal after a WOT datalog or any time I revved high for that matter. Someone else on this forum had similar experiences and found a destroyed ToB. I was expecting some of the same. As it turns out, my TOB came out in 2 pieces. The throw-out and the bearing. The bearing was more or less dry and rattly. The grease on the slide shaft was more like...hard paste?

Also, found the source of what i believe to be the vibration in the clutch pedal which led me down this rabbit hole of replacing the clutch. The friction disk came apart.