my facelift k11 turbo build thread - Cisco's Micra Files

k11_facelift » CMF Member United Kingdom Member since: Posts:	my facelift k11 turbo build thread	Thu 12 Apr 2012 06:57:32 AM
	Hello, this is my first blog as such, on here. It's a 1 litre facelift. I focused on aesthetics the first year I owned it, lowered on coilovers and put it on 13x7 re-drilled Ford Capri Brooklands. I managed to get the 0-60mph in about 10seconds from the 1.0 with cg13 cams and a ga16 airbox, but daily driving was still sluggish, hence why I'm now turbocharging it. Now sporting some widened steelies: And raised it a fair bit for a more subtle look: The turbo is a Garret T2 from a Fiesta RS. And the manifold's built by Frank. I've been putting it together and mocking it up on a spare cg13 which will replace the 1.0 when I get time or get bored. I've got oil lines and sump almost done, throttle body and MAF are in the making. The plan is, to be honest, very similar to franks ghetto build. For me it's a learning experience working with turbos on a budget. I also rate these 1.0 litres, so it would be fun to see what they can do. I won't be chasing figures, just experimenting and having fun too. The head was completely stripped and cleaned. Widened and polished the ports myself, matched the inlet manifold and the gasket. Have also added additional valve spring washers to increase the valve spring rates, so I should be good for 8000rpm+ if I ever needed to go that high. Before: after: I'm unsure whether to raise or lower the compression ratio on it though. These turbos are usually good for upto 1bar of pressure. Any more than that and they're prone to splitting seals quite early. I'll probably work it up to 10psi in time. However I'm unsure if lowering the c/r to the typical 8.5:1 will see the best increase in power and torque due to the low boost. I could raise it to 10.5:1 to hopefully see some good gains in torque, but will the stock 9.5:1 be the best overall?? I'm having some trouble working out dynamic c/r on boosted engines. I'll be using a CGA3 top feed fuel rail with 292cc SR20 injectors. Plan's to remove the washers inside the stock FPR to make it flow more and add a 8:1 FMU. I'll need an adjustable FPR to set the fuel pressure while off boost, and I can also tweak the airflow over the MAF or add a 5th injector if I need more adjustment on boost. Just had Frank build the majority of the exhaust system. It's s/s 57mm bore, side exit. I just need a silencer and a tip. Will probably keep the stock peashooter-backbox on too for some foolery.

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Thu 12 Apr 2012 07:24:07 AM
	heh, looks familiar matt :D my side exit system is nearly finished too :)

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Thu 12 Apr 2012 07:46:48 AM
	not surprised mate, you've done most of it lol. Going to be all me from now on, I hope. What's your thoughts on the c/r for this t2 with no intercooler, either higher boost 8.5:1, lower boost 10.5:1, or somewhere in the middle?

schoona » CMF Member Newcastle Australia Member since: Posts:	Re: my facelift k11 turbo build thread	Thu 12 Apr 2012 08:59:40 AM
	I love it, looks awesome and nice wheel choice! Which coilovers did you get and how do you find them? Wish frank was here to help with my manifold lol

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Thu 12 Apr 2012 10:11:11 AM
	Thanks schoona. I used a FK Automotive street kit(cheap ebay ones) made for a Corsa B that's been adjusted to suit the Micra. It's only the front really, the rears are just shorter dampers, and you use cut springs as the corsa ones dont fit. They work ok overall, smooth ride on average roads, doesn't bounce like stock and there's little body roll in the corners. But bumpy roads however, become very bumpy! Aye, franks about 80mins away from me. I would rather do things myself tbh but I just don't have the time, experience, know-how or patience, and compared to you he's just around the corner eh lol. It only took a couple hours or so to get that downpipe made up. I've been working on this build for nearly a year lol.

bmdubu m3 » CMF Member Sydney Australia Member since: Posts:	Re: my facelift k11 turbo build thread	Thu 12 Apr 2012 11:20:04 AM
	>Wish frank was here to help with my manifold lol" I think we should all chip in and buy him (Frank) a plane ticket to get over here and have him crank out as many parts as he can fabricate for us lol

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 01:07:17 AM
	773 rally cams. 1.0 - 1.3 - 773: 773 - 1.0: spec: 1.0- 196° 5.59mm 1.3- 222° 7.46mm 773- 264° 9.09/9.04mm Now I just need some 1.6mm(+/-) under bucket shims. I've got a spare set, plan's to grind them down but that's looking to be a p.i.t.a. Just researching other methods such as weldfilling, and cutting carbon-steel sheets(baking-trays :p) which should be a closer thickness to start with.

SSUK » CMF Member London United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 06:08:52 AM
	I'm assuming the need for 1.6mm underbucket shims is because the OEM shims are insufficient? Where did you get those from incidentally? They look different to '773' profile cams and also don't appear to have the right markings stamped into the side of the cam by the cam drive. '773' cam below.....

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 07:45:31 AM
	SSUK WROTE: "Why do you need 1.6mm under bucket shims?" Need an additional 1.6mm ontop of the stock 2.5mm shims. I don't fancy paying for custom shims, so I was thinking of grinding a second set of shims to be placed under the buckets. However, the shim I was measuring them on was only 2.3mm and I was just eyeballing the 1.6mm. With the more common 2.5mm shims in and slightly more accurately measured, I'm actually looking for an additional 1mm, give or take as I've still yet to lap the valves in or take into account the final clearances.

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 07:49:42 AM
	Ah ok, I should have refreshed, you've edited the post. These are the cams off ebay, I think you posted a link to them on msc too. "Group A Rally cams" I had assumed they were the 773's, hmm, certainly look different. Same 9mm lift though. I'll have to google the I.D. markings. Thanks for picking up on that SSUK

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 07:54:21 AM
	you would have a mission to grind some stock ones down to 1mm matt ! grinding 30" thou off for my piper ones was hard enough. you might be best to get the seats cut instead eh ? pretty wild looking cam btw :)

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 08:07:02 AM
	yeah I definately won't be grinding them to 1mm frank. How about 1mm thick carbon-steel squares placed under the buckets?

SSUK » CMF Member London United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 08:49:50 AM
	Ah I remember now. There were no closeup shots of the cams, so it was a 'best guess' at the time. As Frank says, they look wilder than the '773' 264s. It would be interesting to see what the profiles on those cams turn out to be. One has to be careful not to go too wild with the stock valvetrain. On a CG10DE I would expect those to result in some pretty high rpms. I am also not a fan of doubling up on shims, call me a pansy but I wouldn't want a shim to get thrown. The attached pic is worst case but it can happen...
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RTK » CMF Member Australia Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 11:14:35 AM
	Wow! Head is needed now! Not double shimming now!

Mickb » CMF Member Perth Australia Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 11:51:34 AM
	Are you referring to shimming under and on top of the bucket? Or both on top? Edit - didn't really look at the pic, ouch! I assume clearances might have been a bit out, plus a weak sidewall.

turbo march-rolling shell » CMF Member brisbane Australia Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 03:56:50 PM
	id say the top shim slipped out and on the downstroke smashed the sidewall

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 04:43:20 PM
	uk_facelift WROTE: "yeah I definately won't be grinding them to 1mm frank. How about 1mm thick carbon-steel squares placed under the buckets? " its only a small contact point underneath and would need to be good steel eh matt, here,s one thats been in mine that,s worn a shiny spot from the valvestem. i,ve had a shim spit and wear a small chunk off a lobe corner, so mine are both underneath, and the small contact point makes it easier to gap the clearances, coz you only have to fettle a bit from the centre to achieve the 1/4 mm gap
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SSUK » CMF Member London United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 05:57:02 PM
	That photo was pretty much worst case. Solid lifters and tophat valve shims are much safer, solid lifters with ground stems are even more so. Sorry if I freaked you out ;) If you're going to turbo that engine, I would say CG13DE cams would be the limit to start with and see where you go. I would expect that cam to be pretty revvy in the CG10, if that's what you are currently working on. The CG valvetrain limitations rarely show their heads though, as most people don't push the engines to an extent for things to become a problem. IIRC James T, (Nis), did have some valve bouce issues in his CGA3DE turbo but given the piston dish and PTV clearances it never translated into a failure. However you could see from the seats on stripdown that valve bouce had been occurring. That photo was actually from a guy running an N/A engine beyond 8000rpm on an unknown cam profile. The engine was built up to a very high spec but it still failed. Later the valve springs were upgraded and he switched over to the later CR series solid buckets with ground stems and never had an issue, (plenty of weight to be saved by using a CR bucket and HR spring retainers). It was ok until he revised things further and started to push past 9000rpm, when he found the stock oil pump couldn't supply enough oil pressure and he fried the main bearings :oO

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 08:19:34 PM
	frank2 WROTE: " its only a small contact point underneath and would need to be good steel eh matt, here,s one thats been in mine that,s worn a shiny spot from the valvestem. i,ve had a shim spit and wear a small chunk off a lobe corner, so mine are both underneath, and the small contact point makes it easier to gap the clearances, coz you only have to fettle a bit from the centre to achieve the 1/4 mm gap" ah good point, I don't think I'm going to fab anything better suited, or even near the quality of the stock shims. SSUK WROTE: If you're going to turbo that engine, I would say CG13DE cams would be the limit to start with and see where you go. I would expect that cam to be pretty revvy in the CG10, if that's what you are currently working on. " The plan is to put this modified head onto the CG10 and turbocharge it, just to see what it can take. And hopefully set a decent 1/4mile time;) I can always adjust the cam timings or even cams if it's too wild for the road. Then when I either get bored or the engines given-up, I'll put the CG13 block in and adjust for practicality & reliability. I'm all up for trying different things, so I thought higher-lift cams that should hold there resale value, would be a worthwhile expirement. I don't think I'll be pushing the limit of the valvetrain, but could do with some 'room for error', obviously dont want that^ to happen. Double underbucket shims it looks like it's going to be, I think.

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 08:22:45 PM
	.

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 08:48:02 PM
	CR buckets are 1/2 a mm thicker matt (so you would only need a 1/2 a mm seatcut eh) and their valves are 2mm longer but you wont be able to fit tophats to the CG valves, there,s not enough stem protruding

Mickb » CMF Member Perth Australia Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 09:37:54 PM
	Frank - sent you an email bud.

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 10:09:10 PM
	Nissan4u.com's saying the part-number for the CR buckets are the same for the CG CGA and QG buckets too, but there's a variety of them for the CR and QG engines, I guess that's the thickness, and they're from 3.0-3.7[mm] So there's a tiny posibility some CR/HR/QG buckets could be 0.7mm thicker than CG ones. Don't think I'm going to be that lucky though.

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 10:22:29 PM
	a CG bucket and shim is 220" thou tho matt (5.5mm ?) and the late CGA/CR buckets are 2mm less iirc (to account for the 2mm longer valvestem) so a shimless bucket + 1 undershim will close your gaps eh (rodger mick :) )

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 15 Apr 2012 11:15:47 PM
	yeah frank, my wording's bad. 5.5mm would sound about right as that would make the CR/HR/QG buckets range from 3mm upto 3.7mm thick like nissan4u says, so with a thick CR bucket(ie 3.6mm) and a thick CG shim(ie 2.7) underneath, it would be about right :)

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Fri 25 May 2012 08:05:56 AM
	Fitted a AFR gauge. I'll find a subtle place in the dash at some point when I've found a nice boost guage to match. It's plugged into pin 105 in the ecu. Results showing it runs lean at cruise until about 60mph then it goes off the scale lean at anything above it. Or if the throttles 3/4 open or more its off the scale lean. (edit: pin 105 appears to run <0.2v when at idle and cruise, then jumps to 13v> at WOT or lean perhaps. The voltmeter says the black lambda signal wire works, but the gauge doesn't appear to agree.) Fitted a set of the GA injectors, they appear to be running fine, no issues at all, pulls a tad better at lower rpm but nothing to shout about. They run borderline lean/stoich at cruise only a whisker higher than the CGs on the gauge, and just like the CG injectors anything over 60mph or more than half throttle it goes of the scale lean again. Plugged the laptop, got readings of 0.8v(rich) at cruise, and 0.2v(lean) at anything more than half throttle, need that 0.8v at WOT too ideally. Unplugged the coolant temp sensor, but that just made it over fuel all the time, even at idle and on overrun and generally felt lumpy. Pulled better around 3000rpm but not enough to warrant the excessive fuelling, so that's been plugged back in. New spark plugs Super4s. Over gapped them and car's behaving well. The GA injectors and Super 4s are definitely doing something. It does hesitate a bit when throttle's been closed a while, like at traffic lights. But it's pulling better at low rpm and acceleration in 3rd is a tad better which makes overtaking a little easier, and just feels happier at higher rpm. There's still loads of room for improvement though ;) Got some shimless CR buckets this week. They average roughly 0.5mm thicker than the CG's. And after shuffling shims about gave clearances of 0.3mm on these 9mm lift cams. Hoping I could remove 0.1-0.2mm from lapping the valves in, should allow more options regarding shims too, as I'm at the thick end of what I have available. CG CR Decided to fit the inlet cam straight onto the 1.0 for a bit of fun. It pulls rather well across the rev range, wants to go higher than 7800rpm. I think I may go back to CG injectors now though, but add a 5th injector for fuel enrichment on WOT. Would be good the get that up and running before adding the turbo too. Fitted a black snooker ball gearknob and extension, not exactly a performance improvement, but fun. And got plans for couple of exhaust silencers and the charge pipe sorted too, nearly there lol.

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Thu 31 May 2012 03:43:36 AM
	Result from the inlet cam's not that great low down at the minute, mid is better and top end is pretty good when it gets there, alot easier to hit the limiter now as it just keeps pulling, I had removed limiter but it feels like it's come back. I guess some more compression would help the low-mid range, hopefully the turbo should be able to sort that out. Or I could alter the timing to close the inlet valves earlier too, but I'll keep it as it is, for now. This lopey idle sounds dirrty 8D Plugged a voltmeter to the lambda signal wire as this afr gauge doesn't want to work correctly. Getting readings of 0.2v at low rpm at cruise or idle, and 1v+ at WOT or 40mph+. Which has confused me even more. Going to have to recheck that. *Edit: bad grounding is what caused the miss-readings. This cg10 with ga injectors and a 9mm inlet cam with a long duration is showing about 0.5-0.7v(stoich) at cruise and idle, and 0.8-0.9v(rich) at wot, in 1st 2nd and 3rd gear anyway, 4th and 5th gear is same as at cruise* :) Turned an old 12-16psi actuator into a 5-8psi one today. However I think the heat from my shite welds has punctured the diaphragm as air leaks now, bugger. Should have fitted an external spring. Got a couple of cherrybomb style silencers, painted them silver. Currently working on a baffled exhaust tip, as I expect it to be loud. Putting together the majority of the charge pipe too. Short and simple :)

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Tue 05 Jun 2012 01:19:59 AM
	This oil feed line has turned into a bit of a pi$s take. None of the expensive aluminium aero hose connectors want to connect to the braided steel n teflon hose. I've tried everything to get them to work/seal but the hose just pulls right off. It's the correct size too apparently :S I'm now looking at other options. A front brake hose shares the same female fitting as the head oil gallery, so a simple joiner would fit, but the banjo will want adjusting from m8 to m10 to connect to the turbo. Another option is to use a regular rubber fuel hose, which appears to be ok, but is this going to be alright long term? If not, my last resort is to import a custom made hose.

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Tue 05 Jun 2012 01:53:38 AM
	i should have a spare kart brakepipe matt :) you need metal braided really, to combat the heat eh

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Tue 05 Jun 2012 02:12:28 AM
	frank2 WROTE: "i should have a spare kart brakepipe matt :) you need metal braided really, to combat the heat eh" Ah that would be great if you have, thanks, do you think this kart brake pipe will be a straight/straighter fit then?

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Tue 05 Jun 2012 02:24:10 AM
	k11_facelift WROTE: Ah that would be great if you have, thanks, do you think this kart brake pipe will be a straight/straighter fit then? " same as mine mate, 1/8 bsp male, with a 10mm banjo

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Wed 13 Jun 2012 05:23:15 AM
	Frank's a star, and supplied me with a ready made 1/8bsp to 10mm banjo pipe for the oil feed. Thank you mate :) Unfortunetly I need one one-size bigger, bugger. That's the last time I use the internet instead of going outside with a ruler! I got my hope up of fitting it this week too. The micra brake hose banjo is actually m10, not m8 as I was lead to believe on some shops website. So, I could go to the effort of filing this 10mm banjo out about 2mm to fit the bolt which sounds a bit risky, or... something else, I don't know, a new turbo ffs Good news though, the boost gauge arrived finally, a regular black faced one and only 1 bar, so slightly better for viewing low boost accurately. Picked up some 50mm pipes along with a bosch recirc valve, and a map sensor for experimenting too. The shop bought items at 4x the price. Charge pipe, just needs trimming to length. Also managed to get a plastic cam cover, which should reduce heat being transfered to the boost pipe running over the top of it. Fuel rail is sort of complete, QG 211cc/m injectors, additional O-rings for a secure fit into the copper pipe, which is a tight fit in the rubbers too. I could really do with finding a propper coilpack manifold though, but the price is silly compared to the CG's. I'll see how the GA injectors I've got in now are first, they should be good for upto 5psi. Here's that rather crazy idle that's all over the place with that 9mm inlet cam and larger injectors, with a quick stamp on the throttle. And the exhaust. Rich eh. Getting used to this afr gauge now, you can tell when it's in closed loop and you get fuel enrichment at wot, which seems ever so slightly higher than coldstart(13:1), measuring what it's doing while bouncing is a little more difficult. Fitted a switch on ecu pin #32 (speed sensor). With the wire disconnected from the ecu I'm getting fuel enrichment in all gears now. Nothing else appears to have changed, I think the ecu only uses this in relation to the rpm to work out gears, and keeps it in closed loop in 4th n 5th no matter what the tps reads. Or whatever, it's working great anyway. I've reset the ignition timing from fully advanced(20* iirc)to about 15* now due to the longer duration inlet cam, which has smoothed the acceleration through the rev range. Noticeably pulling a little better while fully laden with people and baggage. I wonder what it would be like if I advance the cam.

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Wed 13 Jun 2012 06:30:29 AM
	lookin grand matt :) i re-tried the QG injectors recently, and they were spot on for the high comp cammed N/A, but definately too lean on 4psi of boost (you,re gonna need about 60psi+ of fuel pressure imo) the 292 SR injectors really are ballpark size for the stock ecu (as long as you halve the fuel pressure @ low throttle) and mine avoids closed loop now in all gears @ wot even with the speed sensor still connected, purely by high enrichment

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Wed 13 Jun 2012 08:05:16 AM
	ta mate, still got a long way to go, this 1 step forward 2 steps back game is challenging :) I'm in the middle of making a throttle body spacer/adapter(got to rotate the tb to clear the fuel rail), which I want to incorporate a 5th injector on the front. So I think the QG injectors should be alright, or at least it's a good place to start I reckon. I've got some 292cc's ready to be swapped over if needed. But priority is to just get it on and working, then I can adjust and refine, I've got no idea of the scale with everything untested and off the car, but I'm trying to cover all angles. Aye, large injectors and a propper rrfpr sounds ideal atm.

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Wed 13 Jun 2012 05:39:26 PM
	the 292,s will run fine matt, especially if you damper the vacuum signal to the reg (here,s my current damper, the red ballcock float lol :)) its a bit too big tbh, so i,m running it without the 1/2mm restrictor in the pipe, but it softens the reaction of the reg, so that you get a more gradual increase of fuel pressure as the revs rise (and a slower reacting vacuum gauge) and here,s a vid of me forcing the ecu out of closed loop http://www.youtube.com/watch?v=MP6f9xSC_0A&list=UUShAHt9QG4e1Znr-pxWt7UQ&index=7&feature=plcp with a controlled air leak into the mani, and you can drop the fuel pressure that low that it will drive off the scale lean continously (or continously rich if you wanted to) so the closed looping has its limits/peramiters eh
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k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sat 16 Jun 2012 11:20:15 PM
	frank2 WROTE: "the 292,s will run fine matt, especially if you damper the vacuum signal to the reg (here,s my current damper, the red ballcock float lol :)) its a bit too big tbh, so i,m running it without the 1/2mm restrictor in the pipe, but it softens the reaction of the reg, so that you get a more gradual increase of fuel pressure as the revs rise (and a slower reacting vacuum gauge)" Frank did you use a small fuel filter as a damper before, or have I just made that up?? lol if so, how did that work out for you? I was thinking of making a cigar hose by using a 10mm hose and a couple of adapters, but something like an inline fuel filter may be more suitable, cheaper and easier, if it would work. I managed to get an oil feed line sorted finally :) It's part of an oil filter extension kit and about half the price of imported turbo oil lines, that's made of the same stuff. If only I knew earlier, it appears that the oil hose I received before was a size too small which is why the fittings didn't fit, tut. Things I've still got to do: Adapt new wastgate actuator, set and fit. Remove stock exhaust. Cut new exhaust to length, add hangers. Fit silencers, and fit exhaust. Remove sump and replace with turbo oil drain sump. Fit turbo, manifold and oil lines. Cut charge pipe to length and fit. Fit recirc. BOV, hoses and air filter. Install boost gauge. Buy and install fpr. Adjust fueling to suit boost, or vice versa. Most of them will be done on the weekend I fit it, so that's not too bad. Of course I've also got planned: Finish throttle body adapter and 5th injector spacer. Swap intake manifold, fuel rail and injectors. Make 5th injector controller. Complete exhaust baffle/tip. 2 stage adjustable boost setup. Assemble ported and polished head, and swap. Alcohol injection laughs maybe ;)

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 17 Jun 2012 12:23:59 AM
	a little fuel filter, yes matt. its just trial and error tbh, if you damp it too much it goes mad lean for a couple of secs, and with no damping it bogs down a tad as you let the clutch out eh

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sat 30 Jun 2012 03:31:53 AM
	Adapted a Ford Escort RS T3 actuator to fit this Fiesta RS T2 turbo. Set it to open as early as possible which is 10psi, it's fully open at 16psi. A little too high so I'm going to have to do something about that, not welding that close to the diaphragm this time though. Just got to get this exhaust cut to length now, then it's on :) In the meantime I've removed the GA injectors, when accelerating from idle they ran very rich and over time they've got even more richer to the point it stalls easily and became a huge pita. Got a cheapo ebay adjustable fpr to give me some scope before I get the topfeed injectors on.

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sat 30 Jun 2012 03:43:29 AM
	looking good matt :) mine,s got a spring on the rod,(strong spring/low boost, weak spring/higher boost eh)
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k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sat 30 Jun 2012 04:22:40 AM
	ta mate :) that's a pretty smart idea to have it on the rod itself, adjust the strength of the spring by moving the nut too?

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sat 30 Jun 2012 04:41:42 AM
	k11_facelift WROTE: "ta mate :) that's a pretty smart idea to have it on the rod itself, adjust the strength of the spring by moving the nut too?" i find that spring preload adjustments can give very confusing results matt, i just carry different rate/same length springs personally

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sat 21 Jul 2012 06:46:20 AM
	No it's not the update it should have been :( I've been far too busy to do the swap. At Japfest2, Donnington Park. Car's also developed a fault which is putting me off fitting the turbo. It's kangarooing quite a bit and when coming to a stop the revs drop and it can occasionally stall, I've removed the adjustable fpr but that's not at fault, I've now removed the cold start mech and adjusted the idle and throttle screws but that's made no difference, I've replaced the spark plugs too with no result and I've adjusted the ignition timing but it still occurs. So this weekend will be spent testing and fixing that. I also went through a pair of front tyres in next to no time at all, took about 1000miles to go through 5-6mm of tread, rears have worn through about 0.5mm, tracking must be out a fair bit :o So I'm running a staggered set of wheels atm. Good news though, exhaust is done, cut it down to length and fitted the silencers, I've also created a smaller, silenced exhaust tip. Reduces it from 2.25" to 1.75" with a flare, and will poke out beneath the rear of the o/s sill. Hopefully it'll be quiet enough, but it shouldn't be too difficult to add an over axle pipe to exit at the rear with a 3rd silencer. I'm now looking at these, 12:1 rrfpr. http://rover.ebay.com/rover/1//1?icep_ff3=2&toolid=10001&campid=5337873294&icep_item=150857725251 Seems quite cheap, and I guess you get what you pay for, but one of these could give me the scope for the fuelling I'd need.

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sat 21 Jul 2012 07:24:20 AM
	that reg look ok eh matt, you will probably have to try out different springs tho

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sat 21 Jul 2012 08:02:36 AM
	frank2 WROTE: "that reg look ok eh matt, you will probably have to try out different springs tho" yeah hopefully it should be ok with stock injectors at low boost for now, with some dampening. But I'll have to adjust it when I fit the larger top feed injectors. I must have at least one combination that works now though :) Any thoughts about what could be causing the jumpy ride at low revs? Even if it's a complete guess, it'll give me something to try, I've got the weekend off so I want to find it and fix it.

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sat 21 Jul 2012 08:09:57 AM
	i would guess that the reg is set at about 2.5 bar and rises to 6 bar + personally matt ! (mine regulates far lower ) and does the a/f/r gauge go lean when it starts jumping mate ?

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sat 21 Jul 2012 08:56:37 AM
	frank2 WROTE: "i would guess that the reg is set at about 2.5 bar and rises to 6 bar + personally matt ! (mine regulates far lower ) and does the a/f/r gauge go lean when it starts jumping mate ?" Yeah it'll be about 6bar fuel pressure at 5psi boost pressure, bit much lol. afr gauge goes rich occasionally when it jumps, but never lean I don't think. I've got a spare dizzy and a spare tb that I may try out. But I'm worried that I may have had some piston to valve contact and lost compression after cranking it over with a camshaft 1 tooth out. Would rolling it about in gear detect small loses in compression?

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sat 21 Jul 2012 04:32:20 PM
	k11_facelift WROTE: Would rolling it about in gear detect small loses in compression?" i make do with that method lol :) in 3rd gear down our hill, and if it takes 5 to 10 secs for each cyl to to turn then thats ok. a slightly bent valve wont even register any compression eh and if you can change the reg spring to get about 1.5 bar @ idle, it should work fine with the SR injectors eh matt

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Wed 25 Jul 2012 01:26:59 AM
	Compression seems fine, had to do it by hand though as all the local hills were too busy. After some more research, I found if the throttle bodys idle controls have been adjusted incorrectly it can throw the tps readings off which can then result in a jumpy car around 2000rpm, bingo. I've now swapped this t/b for a low mileage one which I've also removed material from the shaft to increase flow. Cold start mech has also been removed from this too. Should have got a better pic. Working flawlessly, for now. TPS set at .50v, idle's around 1000rpm, slightly throatier noise at wot. Performance increase is tiny at best, pointless really, but driving in traffic is smoother now :) While working on the t/b I've found the inlet mani damp with petrol, can see a couple of small pools here next to some burn-like marks. anything to worry about? or just result of oversized injectors and long duration inlet cam?

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Tue 21 Aug 2012 05:30:53 AM
	Finally, I've been waiting for some time off work and I've now changed rotas so I now get a whole week off every 4 weeks, this is that week, so the turbo's going on. Day 1 involved a quick drive to pick up some fresh oil, while also heating the exhaust nuts. Unbolting the exhaust manifold from the engine was simple, but they were the only nuts that would come off. Cut the middle section just short of the backbox. The alternator was removed next to allow the exhaust to drop off underneath. Day 2 involved removing the sump and replacing with one with an oil drain fitting. Fitted the manifold and turbo and fitted oil lines. Day 3 I offered up the exhaust and took measurement of where to cut, and where to add hanging brackets. I welded 2 Cherry bomb style silencers together and spot welded them onto the downpipe, a 90* bend was welded on the other end to finish infront of the rear n/s wheel. Charge pipe was then cut to size and installed, along with vaccuum lines and boost gauge. 12:1 rrfpr was put inline on fuel return. Took it out for a 20min lap of town and filled up with 99ron petrol, all seemed good, comes on boost about 3500rpm, peaking at 4psi at about 5000rpm+. Running rich, but unsure how much and the afr gauge isn't working on this lambda sensor so I still could be running leaning out under boost.. Day 4 I took it for a 260mile round trip to RRG12 meet. Not sure if that was stupid or courageous, but it made it fine. Fuel pump made a constant whine with this 99ron fuel but fine with regular 95ron. Performance is quite good, I was impressed with how well it pulls. Even at 0psi it's noticeably torquer. But atm there's a bigger gain in noise than power. Exhaust is rather loud, but not a typical boy racer hot hatch, more 70's turbo rod, but still, bloody loud. If I had to guess a figure I'd say it's running 75bhp, but it feels like a 100 when you hear the turbo spool up :) Will need to tweek the fuel ratio, atm I'm using stock injectors with the rail set at 3bar allowing the fmu to increase it to 5bar+ on boost. With the stock fpr connected and vaccuum hose on it's very jerky, but sounds healthier off boost. Will also install colder plugs, and adjust ignition timing, also got cams to tinker with again before I think about increasing the boost.

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Tue 21 Aug 2012 06:15:28 AM
	Major progress there matt, whose is the smart white one next to yours lol :D

Seb » CMF Member France Member since: Posts:	Re: my facelift k11 turbo build thread	Tue 21 Aug 2012 05:19:21 PM
	Some Frankastic bits in this car :p Awesome !

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Mon 27 Aug 2012 06:30:23 AM
	Put a couple of missing hose clamps on the charge pipe, this has now increased the max pressure to about 7-8psi at about 5000rpm. It's surprisingly quick at high rpm now, and for a sub 1 litre it has lots of torque, even at 0psi, cruising at 70mph on the hilliest of motorways is alot easier and is out performing alot of bigger cars who struggle. I've covered about 500miles with the turbo on, and it's running rather well, returning about 35mpg now, turbo only kicks in around 3000rpm so it's basically a 1.0 up till then, the power off boost is about the same as before I put the turbo on despite the exhaust and intake. Having trouble removing this faulty lambda though, ideally want to be in closed loop off boost but looking at the sparkplugs I don't think I am, I've now unlpugged it and it's running a tad better for some reason. Got myself a little 400cell cat convertor, going to put this in exhaust before the cherrybombs and possibly weld the the stock rear muffler to the rest of the system, even if it dampens performance it should be worth it for a quieter, legal and MOTable(ish) exhaust, have been treading carefully around the police lately. The recirc BOV, although not actually recirculating, is a lot louder than I expected too and is also totally ruining the sleeperness of the car, may redirect it to blow into the cabin :)

RBLUV » CMF Member Australia Member since: Posts:	Re: my facelift k11 turbo build thread	Mon 27 Aug 2012 01:13:24 PM
	i like it alot

climberjoel » CMF Member Canberra Australia Member since: Posts:	Re: my facelift k11 turbo build thread	Mon 27 Aug 2012 05:30:40 PM
	RBLUV WROTE: "i like it alot" i agree - great k11/build thread - thanks for sharing

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Mon 27 Aug 2012 11:14:38 PM
	Thank you guys :D Hopefully there's more to come, followed by some 1/4 mile timeslips. Still finishing off this ported & polished head, going to get it skimmed 1mm for a 10.5:1 c/r, this should give a bit more power off boost and allow for less pressure to be applied when on-boost. I've connected the side exit up to the stock rear silencer now with some high temp silicon hosing, it's blowing a bit obviously, but the raspy & droning noises have gone, just a much more subtle purr now. Not sure what to do for long-term plans, may try to make a 2" version out of universal parts.

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Fri 07 Sep 2012 07:18:53 AM
	Have covered 400 miles since last update, returning about 35mpg with mixed driving. Running quite well, I tried to get some vids up but I failed. 0-60mph is about 8 seconds now I reckon, but with the current 155/70/13's on I usually end up spinning the tyres in 1st and 2nd. I've now retarded the ignition timing, seems a little smoother upto 0psi but power on boost has almost vanished, have to shift up at 5000rpm. Going to try a few different positions, try and find it's sweet spot, but reliability is important. I've now got the BOV venting into the cabin. Damn loud now, but more inconspicious to other road uses hopefully. Having a nightmare with this lambda sensor. Would heat it up with a 30min drive, or get a blow torch on it, but it just won't budge. Spanner would just round it, lambda socket cammed out, so I've cut it down and used a different socket, that did the same so I've tried welding the socket to it but I can't penetrate the nut. Any ideas?

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Fri 07 Sep 2012 05:15:27 PM
	I would weld a nut on the end matt (wheelnut ?) and turn it while still hot :)

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Fri 07 Sep 2012 11:06:02 PM
	frank2 WROTE: "I would weld a nut on the end matt (wheelnut ?) and turn it while still hot :)" That's not working either, doesn't want to penetrate, the weld just runs off. I'll keep at it for today, but I'm thinking about leaving it and welding in another lambda bolt lol

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 09 Sep 2012 05:53:27 AM
	Car has been missfiring a little now I retarded the timing a touch, approx 13btdc at 900rpm. So I've been pushing this up a little and it seems quite suited to 18, or thereabouts (using consult to measure). Seems nippier at low revs, boost seems to kick in a little earlier too, and makes more power above 5000rpm now. I've now fitted the cooler NGK BKR7 spark plugs. Here's the Super4's that saw about 400miles with the turbo fitted, next to the BKR5's that I've just removed that also saw about 400miles with the turbo fitted. Cam cover has developed a slow leak all around the edges, might have to use sealant on it. Also noticed the coolent has skyrocketed to 200c now with the turbo on, I don't think I've seen it above 140c before. Got to that after about 5 miles. Slam pannel is now hotter than cam cover, eek. And that lambda sensor's stuck in there like a mofo. Exhaust will be off next week so will cut, drill and retap it I think.

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 09 Sep 2012 06:15:31 AM
	Consult will only read the timing relative to where you have "manually" preset the base timing wont it matt ? Ie, set it with a strobe, then adjust it via consult ?

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 09 Sep 2012 06:56:10 AM
	frank2 WROTE: "Consult will only read the timing relative to where you have "manually" preset the base timing wont it matt ? Ie, set it with a strobe, then adjust it via consult ?" Something like that yeah, but I do think the ecu knows where it's manually set. I've marked on the dizzy where 15btdc is, and I know fully turned clockwise/advanced is about 20btdc. Currently I'm in the middle of these markers, and consult(or Nissan datalog I think it is I've got) jumps around 17-20 at 900-1100rpm, dropping to about 4* at 900rpm idle. When the dizzy was retarded slightly past 15btdc, it read about 13-15* at 900-1100rpm and 3* at 900rpm idle.

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 09 Sep 2012 07:15:13 AM
	I set mine at 10 before matt @ about 700 (with a strobe) and tps disconnected. The nonload advance soon kicks in tho eh, and its soon running 40+ deg.!

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 09 Sep 2012 07:55:58 AM
	My load advance goes up to 25 at cruise, then gets upto about 35, occassionally 40 while accelerating. I'm not too clued up with it though, but it's working well atm. It ran fine at stock 15*, then I retarded it slightly but it then ran crap on boost. Now I'm slightly more advanced and it's running great. Odd, I thought more retard would be better/safer on boost.

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 09 Sep 2012 08:43:10 AM
	My stock 1.0 type 4 ecu runs at 15 deg @idle and rises to 40+ @ 4k iirc matt (with no load). But as soon as you apply any load it pulls a lot of that advance back off, and i think when you,re boosting you need to pull even more back, hence why people just run base retard eh. And why piggybacks without ignition control are making it worse still. Micra_pete claimed that the 1.0 ecu runs extra total advance iirc, and when my n/a 1.3 was dyno,d at bromsgrove a couple of years ago the hp rose when i added about 10 deg of retard (but that made it laggy lowdown)

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sun 09 Sep 2012 09:33:42 AM
	Yeah, I've read that the 1.0 ecu has an extra 5degrees of advance. Maybe the ecu takes into account the base timing, and what it displays through consult is that load advance then? I'll have to do more testing and data recording, see what it's doing on boost. Got a wideband O2 kit in post too, better take precautions before I increase power. Running well atm though :)

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Tue 18 Sep 2012 11:24:32 AM
	This week I've been making a 2" stainless version of the original backbox, using the stock Micra backbox and universal bends. The stock one, roughly plumbed up, quietened it down alot without reducing power too much. Went this route to keep it relatively quiet and less than a 1/4 the price of aftermarket Micra boxes and cheaper than other ready-made parts too. Stock, cut open. 3 chamber setup. Drilled spot welds and bashed the insides till loose. Emptied. 1 chamber, 2 perforated pipes, 2" throughout. What it'll sound like I don't know. Welded up. Alot of welding on this mini project, I got better as I went along. Subtle :)

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Tue 18 Sep 2012 11:34:35 AM
	Flange welded on Other side started. Last bit connecting side exit upto rear backbox looks a little tricky though.

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Thu 20 Sep 2012 05:54:10 AM
	Slightly awkward bend, tricky as I'm out of bent pipe. And out of time, silcone hose and tape will do until next week. Wideband sensor in place. Innovate MTX-L wideband controller and gauge. Finally got around to it, it seems I've been running at about 13:1 on a cold idle, 15:1 at cold cruise and 12:1 on boost while cold. when warmed up idles about 18:1, cruise about 13:1 and boost fluctuates & creeps between 11:1 to 15:1 - @ 6000rpm the power starts to drop as the the afr gets above 15:1. But more tesing needed. Breather hose connector seem to have a built-in 1 way valve, or atleast it restricts air entering the head, was a little woried by the boost pressure pressurising the case, but surprised at the lack of oil coming out the other open port. Anyway I put a spare on the end so no boost pressure's entering the case and same amount of boost leak as before, will block it off at some point.

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Thu 20 Sep 2012 05:36:48 PM
	That cruise at 13:1 sounds like the fuel pressure is too high to me matt (assuming you,re still running the stock lambda too) Have you tried any softer springs in that fuel reg ?

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Fri 21 Sep 2012 05:28:45 AM
	Vacuum hose isnt connected to stock fpr so it will be at 3bar i think. And lambda isnt connected either atm, but ill get that sorted. Not tried any softer springs, its seriously leaning out on boost, 16:1 at 4psi, 18:1 at 6psi :/ so will try bigger injectors first then bring pressure down i think ?

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Fri 21 Sep 2012 05:44:52 AM
	I think i would run the stock lambda matt, (fueltrims/limpmode etc). And the pump will only supply up to 5 bar ish i think mate, so the 12:1 will have limited scope unless you drop the base pressure eh :)

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Fri 21 Sep 2012 06:12:27 AM
	Still fighting with this stock lambda sensor though lol, but this wideband has an additional narrowband output, so I'm going to try and connect that up, hoping it will help with fuel economy, try and run closed loop at cruise. Ah right, I thought the fuel pump wouldn't be able to cope, and it keeps getting louder, so I've got a skyline one in post to replace it. Moving in the right direction now, wideband O2 kit is a very good tool.

frank2 » CMF Member birmingham United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Fri 21 Sep 2012 06:24:36 AM
	Yes the wideband sounds useful matt, i,ve opted for a nistune board instead eh :) I think that if you,re using a 3 bar base pressure, then after about 3 psi of boost (ie 45 psi + 12 x 3) then the pump will be maxxing out eh . Where,as with a lower base pressure and bigger injectors, you have more in reserve eh

asdame » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Fri 21 Sep 2012 06:26:53 PM
	U tried disconnecting the speed sensor wire between the speedo n ecu? Cos that makes the stock map lean out in 4-5th gear for some reason when on a certain rpm and speed combo

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Sat 22 Sep 2012 04:53:33 AM
	Yeah. Speed sensor has been disconected and trialed when n/a months ago, been running flawlessly. Just gradually leans out when increasing boost pressure.

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Mon 24 Sep 2012 11:57:24 PM
	Here's a vid of the wideband next to the narrowband at a 30mph cruise in 3rd and 4th gear, warmed up properly now. It's like this in all gears at low rpm at cruise. With about 13:1 under acceleration off boost, 11:1 at wot off boost but when boost comes on it gradually leans out as boost pressure rises. This cruise isn't too bad I think, considering Lambda sensor's not connected to ecu yet, but limited as a change in rpm or throttle position can push it to 13:1 easily. And a video of it at a 30mph cruise in 4th and 5th, while cold, so no narrowband signal. Followed by WOT and fuel enrichment. 6 seconds in it goes upto 22:1 as throttle's closed and injectors cut off.

k11_facelift » CMF Member United Kingdom Member since: Posts:	Re: my facelift k11 turbo build thread	Wed 26 Sep 2012 03:18:00 AM
	Went to put the Skyline gts-t fuel pump in today. Should have been an straight forward swap, but I had heard that some late K11's came with skinnier fuel pumps. Turns out mine has the skinnier fuel pump :( Skyline on top, Micra underneath. How it looked in the tank. So I bodged it, trimmed the swirl pot and secured it with an additional cable tie. Result is about the same as before, slightly noticeable gain in throttle response, but still leans out under boost. bugger. Here's a longer vid of the narrowband, wideband and boost gauges during daily driving. Accelerate with wot at about 3min and 4:30min in. Boost gauge isn't clear but goes upto 0psi under light load with 13:1, and climbs upto 5psi in 2nd at 5500rpm shift with about 17:1.