My custom holset install - (The H1-3558x), **underway currently**

[turboglenn]

IF it isn't one thing it's another (or maybe i should just say "it's a DSM" )

Anyway, after having fixed all the oil feed leaks and other related places that dripped oil i found that iSTILL had a decentlyt fast dripping leak at the turbo which was coming from the piece of hose connecting the t3/4 return flange to the 2g OEM return that had been cut in half on my first t3/4 hybrid install 10 yearsago (pretty long life from the hose either way IMO )

I Also have another PITA issue that arose while i went to take a customer for a ride this evening. I Went to move the laptop and the weak piece of plastic in the USB port snapped off leaving the only (last) unbroken USB port on the thing inoperable A trip to best buy for a USB PCMCIA card will cure that but as for the turbo line i will have to get it in the light tomorrow and make sure it is in fact the rubber line and not a gasket at the flange.

We shall see come light, but the car is about to make a drive to the east coast coming up so i am hop[ing to establish "check point" members to be able to have as emergency contacts along the way should something go wrong by chance and leave me needing something i either don't have, can't get where i am, or didn't happen to bring the tool for that part with me..

So if you're in between Nebraska and West Virginia along the I-80 route(forgetthe other roads i'll be on) PM me with some contact info

 

[vash_1010]

Any signs of separation?

 

[turboglenn]

Any signs of separation?

seperation of what part bud? If you're talking about the oil line, I just bought replacement line from parker and am not even going to look for the crack/leak because i know it's the line that's leaking at this point and i'm just gonna replace it to be extra safe.

As for the gasket, I pretty sure it's holding tight because the areas where iwiped it clean there's no oilup that far, it's only coming out of the rubber hose.

well i'm half occupiedand talking in circles probably so I'm gonna hop off here and get to fixingthe car

i'll updateasi make progress

_____________________________________
update

Well, I couldn't stretch the thick red parker hose around the cut off half of the 2g OEM return so i had to go get some more heater hose (what i had used the first time, but it held up almost 10 years) and that's what i'm running for the return for now i guess.

The leak is gone and as long as it holds my oil foir my trip out east and back i'll be happy and can go from there as far as replacing it with something with -AN fittings to make it purdy and nice (I have a spare N/T oil pan i'm gonna welda bung into in order to make it work with some -12 or -16 (which ever i can make fit on the CHRA and not interfere with the compressor backing plate on the H1c

well, it hadn'tleaked at idle anmd fre revving but after ashortdrive i found that the flange gasket is leaking a bit too i've cut somefrom paper gasket material but not sure they'll hold i'll check the diesel shop tomorrow for a real lead plated gasket to use on this

I also need to change a rear U jopint i hear squeeking before my journey this week

++++______________________QUESTION

anyone ever use a paper gasket on tthe turbo return feed?i've either not used one period and just a light light coat of high temporange or used the metal/lead units. But i traced and cutout somepaperones just in case but am questioning if the paperwill hold up again'stthe turbo's heat

 

[forcefed86]

anyone ever use a paper gasket on tthe turbo return feed?i've either not used one period and just a light light coat of high temporange or used the metal/lead units. But i traced and cutout somepaperones just in case but am questioning if the paperwill hold up again'stthe turbo's heat

I've used the thick cardboard type gasket sheets. Works fine.

Not sure which angle your speaking of but have you seen these?

AN 10 Turbo Oil Return Drain Flange Angled T3 T4 T04E on eBay!

A turbo I ordered came with one. The straight fitting would hit the back plate. Sounds similar to what your describing. I didn't end up using it. If you'd like to try it I can send it to you.I believe it is only a -10 though.

 

[turboglenn]

I've used the thick cardboard type gasket sheets. Works fine.

Not sure which angle your speaking of but have you seen these?

AN 10 Turbo Oil Return Drain Flange Angled T3 T4 T04E on eBay!

A turbo I ordered came with one. The straight fitting would hit the back plate. Sounds similar to what your describing. I didn't end up using it. If you'd like to try it I can send it to you.I believe it is only a -10 though.

that might work, -10 is about 5/8th and that's what i'm running for a return size now with the OEM 2g return and the straight barb flange, so i'd be down to give it a try if you wanna put it to the cause I thin k that angle would fix what i mean about the backing plate problem

 

[bastarddsm]

I Also have another PITA issue that arose while i went to take a customer for a ride this evening. I Went to move the laptop and the weak piece of plastic in the USB port snapped off leaving the only (last) unbroken USB port on the thing inoperable

I have done that. I got a USB extension cord, and soldered it in place of the jack. Now I have a USB pigtail.

anyone ever use a paper gasket on tthe turbo return feed?i've either not used one period and just a light light coat of high temporange or used the metal/lead units. But i traced and cutout somepaperones just in case but am questioning if the paperwill hold up again'stthe turbo's heat

I have used paper gaksets with no issues. I usually just Ultrablack, or Ultracopper em anymore tho.

 

[Dyesuperman]

You can fit a 1" (-16an) bung on the turbo side, the hose just needs to be clamped on instead of slipped on or screwed on like a regular -an fitting. Just need to dent the fitting a little bit to clear the vband clamp but it doesn't impede flow at all

 

[turboglenn]

I have done that. I got a USB extension cord, and soldered it in place of the jack. Now I have a USB pigtail.


I have used paper gaksets with no issues. I usually just Ultrablack, or Ultracopper em anymore tho.

I bought a cheap PCMCIA to 2 USB port card to try. I also will try the paper gasket but will keep sealants MINIMAL, maybe even just use copper spray so it doesn't spread.

You can fit a 1" (-16an) bung on the turbo side, the hose just needs to be clamped on instead of slipped on or screwed on like a regular -an fitting. Just need to dent the fitting a little bit to clear the vband clamp but it doesn't impede flow at all

you have a picture of this setup? I'd love to check it out and see what i can get away with on the v-band style backplate obstructing things the way it does. I still prefer it to the snap rings any day. And as long as i'm not having oiling problems i'm not too worried that my return is too small

ONe things i've noticed and i'd love to hear from others opn this.... If you disconnect the oil return from the oil pan with the oil level where it should be on the dipstick, the oil id above the return tubes opening which holset forbids oin theor install instructions... anyone else ever notice the oil being above this level with it to the fu;ll mark on dipstick????? I'm just starting to wonder if soemthing is not right on my engine's dipstickor something since it's this high on mine. as far as i k now it;'s the right dipstick, it was originally came with a white bent round metal top ring on it and i made a new handle when that broke, but i'm thinking i might have the wrong dipstick

with oil cooler i hold just at or over 5 quarts of oil. but it does seem to run queter with it down a quart

 

[Dyesuperman]

I bought a cheap PCMCIA to 2 USB port card to try. I also will try the paper gasket but will keep sealants MINIMAL, maybe even just use copper spray so it doesn't spread.



you have a picture of this setup? I'd love to check it out and see what i can get away with on the v-band style backplate obstructing things the way it does. I still prefer it to the snap rings any day. And as long as i'm not having oiling problems i'm not too worried that my return is too small

ONe things i've noticed and i'd love to hear from others opn this.... If you disconnect the oil return from the oil pan with the oil level where it should be on the dipstick, the oil id above the return tubes opening which holset forbids oin theor install instructions... anyone else ever notice the oil being above this level with it to the fu;ll mark on dipstick????? I'm just starting to wonder if soemthing is not right on my engine's dipstickor something since it's this high on mine. as far as i k now it;'s the right dipstick, it was originally came with a white bent round metal top ring on it and i made a new handle when that broke, but i'm thinking i might have the wrong dipstick

with oil cooler i hold just at or over 5 quarts of oil. but it does seem to run queter with it down a quart

I can probably snap a few pictures of it on the car. I completely forgot to take pictures of it off of the car for some reason when I had it made. The oil is above the return when the car is off because oil sinks to the oil pan when it isn't circulating. When the oil pump starts working and oil flows through the engine I am sure it isn't above the return line

 

[turboglenn]

yea, would love to see the pics when you get a chance to snap a few. I got the PCMCIA cardworking today and started setting up for pumpfuel again since i doubt e85 will be easily found across the US on myroute. I"M hoping there's nothing i haven't thought of in the sense of swapping back to pump fuels (things like how the initial e85 conversion clogs up fuel filters and such)

I am also looking forward to the cleaning gasoline is supposed to provide on a systemthat's been ran solely on ethanol for the last several years. BUt i am willing to bet tuning a set of 1600's on pump gas for light throttle cruise is not going to be the most fun i've had in a while, but i'm always up for a challenege (as long as it's not the challenge of repairing something roadside on a 1000+ mile trip )

 

[BoostedTalonTS]

^ LOTS of good info here... Thanks Glenn
(subscribing)

 

[nfernotalon]

Hey Glenn I have a pic my return set up so far for the h1c in the questions for Justin thread. If you don't mind looking at it let me know what you think I believe it's 10an and I'm gonna use a 2g oil return line also. Thanks.

 

[turboglenn]

Hey Glenn I have a pic my return set up so far for the h1c in the questions for Justin thread. If you don't mind looking at it let me know what you think I believe it's 10an and I'm gonna use a 2g oil return line also. Thanks.

I'm working on a customer car right now doing a front mount install and piping kit (just taking a short break) but i will look at it here when i get done tonight.

next time though instead of putting a personal request in a thread just PM me, a lot of people do every day and i don't mind at all, Im' always glad to help when i can

 

[turboglenn]

Well, there's not much to do with the install but i do have a little progress to report on how the thing runs. For the most part i've been on about 25psi and enjoying it untill warmweather set in and robbed somepower from me.

So today i started looking for ways to get more boost from the Profec with the industrial pneumatic valve i used to replace it's broken on. I ended up addind a MBC in line with it to the bottom of the wastegate. Just going from 25-26psi up to 28-29 was an amazing increase in power. I got my 1-2 wheel spin back and third is pulliong harder than ever!@

peak boost or full spool happens around 4200 if starting from a bogging pull, and between shifts anywhere over 4700 and the recovery is almost instant. The car is definintely pulling MUCH harder than it did on the 57 trim at the dyno's 438hp/396tq (i'm guessing it's making around 480hp or so)

Even at these levels of 28/29psi i'm topping out timing at 19* (starting at 14/15* at the full onset of boost) AFR's are 11.8 - 12.1:1 and i'monly working the 1600's to about 52% IDC (most i've seen) So i've got room to grow,i just need some H11's/A1's to hold the head down better

70-90 times are under 2 seconds (abnout 1.5if i had to guess since i can't log MPH)

Overall the more i push it the happier i am that i gave up the 67mm unit for the HX35/40 hybrid

 

[forcefed86]

Get that thing to a drag strip asap! Just had my own run crappy strip shake down. 12.2 @ 119 20-22psi. 100% DC by 7300. I wanna see what that hx35 can do!

 

[turboglenn]

Get that thing to a drag strip asap! Just had my own run crappy strip shake down. 12.2 @ 119 20-22psi. 100% DC by 7300. I wanna see what that hx35 can do!

That's pretty good ET for only 22psi, the difference between 22 and 28psi on a holset is INSANE! I've done a lot of turbo work from installing to tuning and even on some of the larger units i've never experienced an airflow gain of the size i got when upping the hybrid i built from 25-26psi to 28-29psi, I mean it literally had to have gained 40hp.

Only issue i'm having now is spark blowout here and there. Sometimes i can make a clean pull at those pressures and sometimes it will spit and pop once or twice per gear. I believe it's because of the overly rich AFR's at that level of boost (have it at 12.0-12.5atanything below 27psi but above it i'm in the low 11's which is just too rich formy setup right now)

I'm thinking about getting new plug wires, my MAgnecores are around 10 years old so i'm thinking that might be part of it, and i'm also only running 3.0ms of dwell time (might need to bring it up to 3.5 in hopes of more spark)

Although i wanted to sell my MSD DIS-II i'mthinking i also might have to slap that back on if nothing else. I"m running NGK BR7ES plugs right now and they are side gapped at .019" and they are doing MUCH bettter than the sameplug with normal gapping still at .019", but i'm sure i can iron out the spark issues with some AFR tuning and maybe a few tweakstothe ignition if nothing else i'll start with new wires

The car (or i should say the turbo) has never ceased to amaze me with the gains it makes with every PSI added tothe controller. I"m seriousely at this point hoping to be able to afford some L19's here soon now tha ti have the injector for it

The Doctors have told methat my injuries are not making progress and that i will need more extensive surgeries comiong up so i'm finally biting the bullet to get on disability so having medicaid cover the monthly medical things should open up some cash for me to get a few littlethings like L19's, maybe sell the DIS and get the Dyna ARC-II (As well as replacing the windhsield that's been cracked for 4 years )

Anyway.. FUN FUN FUN< that's what holset means in german i was told

 

[red1993gsallmt]

Glen, is it the e85 that makes you have to run such a small gap? On 93 pump ive always have gotten away with 30-35psi with a .026 gap on br7es plugs with stock coils, maybe its because I run such low timing. just courious

 

[bmoha7321]

Sorry to hear that Glenn. I too am going thru more injury related crap. I blew out c6-c7 disc end of 09 and lost the use of my left arm for 6 months until I had the vertebrae fusion surgery. And now it appears I blew out c7-t1 and my left arm isn't working well again. So getting another disc replaced. More titanium bolts and screws. I wish you the best man.

 

[turboglenn]

Glen, is it the e85 that makes you have to run such a small gap? On 93 pump ive always have gotten away with 30-35psi with a .026 gap on br7es plugs with stock coils, maybe its because I run such low timing. just courious

You know,i'mreally not sure.. eversince removing the DIS-II i've had to run gaps as tight as .016 to get it to fire off at ~30psi and not have it blow out here and there. I never ran that kinda psi opn pump gas (but on a side note i'd like to know what kinda timing curve you're riunning on pump and 30+psi)

Sorry to hear that Glenn. I too am going thru more injury related crap. I blew out c6-c7 disc end of 09 and lost the use of my left arm for 6 months until I had the vertebrae fusion surgery. And now it appears I blew out c7-t1 and my left arm isn't working well again. So getting another disc replaced. More titanium bolts and screws. I wish you the best man.

Man, i'm so, so sorry to hear that bro. Chronic pain and injuries to the spine, knees and shoulders are things i wouldn't wish on the people of my "most hated" list. it realy is debilitating in all aspects of life. I"ve finally went to get my disability with a lawyer (got the big name TV guy from here local )

So that should take care of my last few surgeries (i hope) and get me back in school to compolete the last bit of my engineering degree.

 

[bmoha7321]

Hah! No kiddin! I was thinking the same thing! I've got about a year and a half left to complete my mech engineering degree provided all my credits transfer from Syracuse U to U of Wisconsin here.

 

[forcefed86]

Wonder if it's time for a new coil pack glen? or as you said could be wires. I'd spike to 35psi or so on the 16g and never had spark issues. Using cheap auto zone wires and factory IGN. I'm gapped at .026 as well. Used NGK Br8es and tried BR9es as well with no issues. This was all on e85 running 4gph of washer fluid through the mix as a well.

red1993gsallmt I'm all for hearing an explanation for 30psi on on pump gas as well!? Was this with the hx40? I'd love to ditch the e85 and run the e30 they have locally. Shoot me a pm or start another thread if you don't mind. Did you run the projected plug?

 

[turboglenn]

Wonder if it's time for a new coil pack glen? or as you said could be wires. I'd spike to 35psi or so on the 16g and never had spark issues. Using cheap auto zone wires and factory IGN. I'm gapped at .026 as well. Used NGK Br8es and tried BR9es as well with no issues. This was all on e85 running 4gph of washer fluid through the mix as a well.

red1993gsallmt I'm all for hearing an explanation for 30psi on on pump gas as well!? Was this with the hx40? I'd love to ditch the e85 and run the e30 they have locally. Shoot me a pm or start another thread if you don't mind. Did you run the projected plug?

I really don't think it'sthe coil packs, I had removed them and Ohm'ed out all the sets i have (got about 5 of them) and these were perfect so i have been running them since summer.. I still think some of it's to do with the 3ms dwell instead of the required or specified 3.5 that these coils need or ask for in their specs. I had it set super low to avoid cross over in the J&S unit while running the DIS-II a while back and just never changed itback to 3.5

I'm really starting to lean towards the Magnecores going bad, after all they are about 10 years old now. I did have some cross arcing issues with them because the seal at the "cap" where they plug onto the coils had deteriorated but i covered them in silicone and that went away. But, no matter what they are 10 years old, been oil soaked for most oftheir life from oil blowing out the filler cap under boost some times, both because of a bad cap gasket and case pressure (need to install my VC with the -8 vents but i need to finish the polish job on it first)

Now that summer's here i really want to slap my oldtokicos' back on with the old hyperco lowering springs so she isn't sitting like a monster truck anymore (i left it high for winter driving since i sold my bronco a while back)

We just got my friends carbon eclipse making boost today, we were baffled that it wouldn't make over 13-15psi last night on a PTE6765RS turbo and today after pulling another shops DP off it I spotted that the inside of the flex had bunched up and shrunk down to about 1.25inch diameter (was like breathing through stock piping lOL) I didn't have any Flex pipe so since the engine is on solid mounts i replaced it with a plain piece of 3" and we isntantly had pressure off the wastegate which was 21psi spring combo, and i spent the rest of the afternoon tuning that car, so i haven't messed with mine much

The weirdest thing is that my friends car has a DIS-II on it and it's plugged in and functioning and even with the HUGE bluw wires with teh seperate ground straps we were getting blow out at 21 psi constantly, running E85, BR8ES plugs gapped at .026". I tried to get him to change them but we had so much todo we focused on other things for now

 

[bmoha7321]

My NGKs 10mm wires went bad after about 8 years.

 

[red1993gsallmt]

You know,i'mreally not sure.. eversince removing the DIS-II i've had to run gaps as tight as .016 to get it to fire off at ~30psi and not have it blow out here and there. I never ran that kinda psi opn pump gas (but on a side note i'd like to know what kinda timing curve you're riunning on pump and 30+psi)



Man, i'm so, so sorry to hear that bro. Chronic pain and injuries to the spine, knees and shoulders are things i wouldn't wish on the people of my "most hated" list. it realy is debilitating in all aspects of life. I"ve finally went to get my disability with a lawyer (got the big name TV guy from here local )

So that should take care of my last few surgeries (i hope) and get me back in school to compolete the last bit of my engineering degree.

Come on guys, Ive always been able to run 30+ psi with the hx40 even without meth on a evo 8 timing map, and thats on my 2.3!!!! You guys should be able to add even more timing on your 2.0s at 35psi and pump gas!

 

[turboglenn]

I'm not having any issues with how much timing i can run, I"mhaving spark blow out problems.