Short story of my car, wich i bought in 2015, from factoy it had 2.5 142kw engine...
1 month pure stock, then tune to 160kw. Not enough, bought 16t turbo. Local guy tuned motronic 4.4, made pops and bangs, was fun 😄*never went to dyno, butt dyno says it had around 190kw. Broke engine after summer, bent all rods coz i didn`t care about engine health anymore since i knew it wont hold 300+ safe.*
2.0l 132kw engine from s60 (the one with 9.5 compression)
k24 turbo, e85, walbro 255, siemens deka 630cc, some crap fmic from iveco daily, self tuned, made 302hp/500nm at 1bar, was very rich at dyno, lots of misfires coz of that (at street was all perfect at 1.6 overboost, tappering to 1.4 bar, guesses around 330hp, but turbo was old, tired, broke the turbo after 3 months of driving). Bought forged rods, opened engine, and then realised 139.5 ones wont fin. Overall engine was in good shape, but i was lazy to put it back together, everything went to metal, oh well... Then bought hx35 turbo with 54mm 7 blades wheel and started to look for b5234t engine.*
Found engine, with forged rods, very cheap, had only 4k km after rebuild. Skipped year, was gathering parts suchs as full alu radiator, tubular manifold, 600x300x100mm intercooler, piping, brakes, wheels, standalone ecu..
Winter ended with making all engine wiring for Ecumaster Emu Classic, puting brakes, etc.
Found Brembo calipers from alfa romeo, bought Rottinger slotted disk, 336mm front, stock diameter rear. Ferodo premier pads, some nice BBS wheels, 8j front, 9j rear. with 225/45 semi slick tyres up front, 245/40 rear. Also changed fuel pump to Walbro 450, did some wiring upgrade for it, also bought siemens deka 875cc injectors, FPR regulator. After puting everything together, spent maybe a week, till i managed to start the car with standalone ecu without tune, no base map, nothing, 5 evenings sent just to make the car start.. Few more days to make it run from garage on herself. And sadly, engine wasn`t in so good shape as i thought, 30km later, just when i went for base tune to a locar tuner, lost oil pressure at 1.3 bar WOT 3rd gear, spun all bearings, 2 rods became black, 2 bearrings melted and became part of crank, yay! Good thing i had crank from 2017 season engine and new set of cxracing rods. Rebuilded engine with new crank, new rods, stock pistons and rings was still in good shape, so i left them. King racing rods bearing, King main bearings, D5 oil cooler, etc etc. Finally engine was runing great, did 100km break in, changed oil for Valvoline vr1 10w60, went to tune it again. Lots of boost leaks, boost coming very slow ant late, 1.5 bar 435ag/580nm... Tuner said my engine cant breath or turbo is maxed out (boost solenoid DC at 50% only, with 0.8 bar base pressure spring. Okay, weekend at garage, fixing boost leaks. Decided to tune it myself, since i had pretty much good map allready, good ignition table. 1.9 bar "overboost" tappering to 1.8 at 6k, 1.7 at 7k rpm(or backpressure, or wastegate spring was over, 100% duty cycle and couldn`t raise boost anymore). Injectors duty ~88-90% at 3.5bar base fuel pressure (siemends deka 875cc@3bar). 449ag/644nm, sounds a bit better, finnaly car is kinda fast, even without LSD i managed to make 0-100kmh in 5.5s, and 9s 1/8 mile in few tries, even did 8s 100-200 with rolling anti-lag. Without it, best i managed, was 8.6 (rev`ing to 6.8, when no point to rev more than 6.2 as i saw later, after looking at logs and trying different variations of gear change). Boost by gear* helps a lot. Sadly, B.itch broke after 1.2k km......
Some pictures from build before engine decided to brake.
And look what broke! Log was clean, no detonation, no lean afr, nothing bad. Just few pulls, and lots of smoke...* Spark plugs looks good, still have no idea what went wrong 😞Bye bye cylinder #5. Funny thing, all rest looks good, pistons, rods, rings, ringlands, bearings, everything good everywhere except #5..* TBH even #5 piston didn`t broke, just melted a bit from cylinder wall.
Cyl #5 rod bearings, ony ones wich in bad shape
Piston looks like it hit the head, but on head no marks indicating this happened, also i don`t understand how this is possible, unless crank broke, or somehow it got bent in few pulls. Coz this happened few days after last dyno. Overall i drove around 400km with 1.8-1.9 bar, and i took this car to drive not for simple cruise, but for WOT runs,* to have some fun. (don`t mind grooves from valves, not my job, old engine owner broke smth, and used these pistons in next engine, budget builds, you know... 😄*)
AAAAAAAAnd plan for 2020
Got tired of braking stuff. Bought built b5204t (that old one, with 77 stroke, 8.4 comp. ratio). Engine was built 5 years ago for drag racing, by local builders who proven by community, they have hands how to build engines. Domes around cylinders, custom head studs, custom FCP rods (4mm wider than china ones). Fully rebuilt and ported head with hidro lifters. All cleaned, changed what was necessary, everything measured. Engine was never fired, a guy left project for few years. Took it apart for cleaning, didn`t liked glyco bearings (not sputter ones, wtf).* The difference of rods/pistons 2.0 vs 2.3 🙂
Yes,* both rods is same lenght! Since there is no 2.0 forged pistons, i will make 2.3 from this block, don`t like the design of 2.0 pistons, and since i`m lucky with oil pressure, it will be way easier to get 90mm crank instead of 77 one, just in case, you know 😄
Some pics of block and head ports
Soooo, winter was lazy, now coz of virus, things not going fast as i want also. Engine is almost ready to drop in, LSD is in. I actually was kinda surprised how gearbox internals are in excellent shape.
Idk if i was smart, but ordered wiseco 81.25 oversize, block was in really good shape, just needed minor oversize. MLS headgasket ofc, 12.9 metal head studs, torqued to 130nm with arp lube. I did rings kinda loose, 0.5mm top and 0.55mm 2nd. King`s main bearings, glyco sputter rod dones, RN oil pump, d5 oil cooler. A friend helped me with head porting, went all in basicly. And sadly, no cams for now, will try GLT ones (maybe someone can give some guidelines on how to time these cams for 64mm turbo?). Waiting for custom turbo to arive in few weeks, then i can drop engine in and take car to shop for exhaust manifold and downpipe, some pipes fabrication. Oh, and also bought kl racing intake manifold. That thing will need more work than i expected. Lots of gasket matching, cast/welds grinding, vacuum ports welding (or maybe i`ll just weld some plate for "vacuum tree"). Dunno yet, but i think i`ll need to modify termostat housing a bit, for manifold to fit, also relocate temp sensor somewhere else.
Spent half day porting that "almost bolt on" kl racing manifold (some casting still gonna need some shaving, i didn`t had enough lenght drill bits to do that for now). Holes for bolts needed to be raised up about 2mm, runners needed to be shaved kinda a lot. Thermostat housing will need 20mm adapter plate to be raised up. Also gonna need adapter for 960 throttle body (all would be fine if not TPS sensor and spring). Oh, and also i had to cut some of the flange of intake, it was hiting thermostat housing lower parts.
Made throttle body adapter, termostat housing adapter, changed place of CLT sensor. Manifold is welded, ghetto connections for vacum lines, idle, brake booster. Everything kinda fits, except TB touches coolant radiator fan housing (will try lower all radiator about 10mm, problem should be solved, else i`ll just cut a piece from fan housing). Still need to figure out how to connect cable to TB, make some bracket to hold oil level dip stick, connect few coolant hoses, some minor things.
Also, finally my turbo arrived. Turbosystems HX4064b1, proven for solid 750 at the crank.
Well, things are going slow. Kinda finished intake side, changed control arms to pre `94 with poly bushing from kl racing, changed gearbox torque mount bigger bushing to poly one, right side mount to MPRE custom one, did some PCV "fix" for high boost and waiting for my exhaust manifold to be finished. Like allways, when i`m doing something to the car, keep forgeting to make pictures if everything will go by the plan, car should be runing in a week, max two.
Manifold is finally rdy, machined flanges surfaces to be flat, did some hammering to few runners, needed to make 2mm extra clearance near valve cover Turbo is in! Cold side had to be clocked a little more, than it is on the photo. I`m surprised how much room left everywhere around turbo (except rear pillow bracket)
So i`ve been working on car past few weeks almost at nights, to get it ready for local drag event (1/4 mile). Only few photos from all finishing touches Got car tuned only few days before event, no time even to learn how it drives, but i`m very happy how this family sedan turned out. Pulls like a train (need cams, spings, engine feels like it asks for more rev range, ol), no leaks, no bugs, spent all weekend driving quarter mile 1 run after another with 33+ temperature outside, very hot day. IAT was 50-60, sometimes 70c, car holds like a tank Drag event was held in one of town public streets, so u can`t expect good grip there. I also saw how bad is "drift" semi-slick tyres with huge TW numbers, needs loooots of heat to even start to work a bit. On the dyno we had falling boost, not reaching it`s target, supposed to hold 2.1bar, but ended with 2bar, i think with 2.2 solid, on colder day, could be 600 easy. 1st day we tuned with 6800rpm rev limited (don`t ask why, tune error), we made 500 with 1.85bar, played with ignition, a bit more boost, and few runs later 550 with 2.1bar, power firstname.lastname@example.org rpm. Fixed bugs, went on dyno next day, a bit hotter day, +10c higher intake temps, just with rev limiter set at 7500, made 564, even boost was a bit lower