my echo turbo build log

[ipwnr]

hi guys im starting a new build on my echo. i got a td03 turbo for free from school and that just gave me enough motivation to actually think about boosting the little car. as of now i have the turbo and a small intercooler off of a mazda millenia. currentley what i have done to the car is

echo rs leather steering wheel
echo rs aluminum rims
echo rs seats
removed spare tire
power steering delete
a/c delete
changed clutch (used a toyota celica clutch and pressure plate)$80 off ebay lol
muffler delete
turbo gauge 4in1
aem fi/c

and now a list of things still to do

install aem fi/c
custom turbo manifold
oil lines / coolant lines
intake piping
tires (planning on hankook optimo 4s)
rebuild turbo

i dont expect to get much hp from this tiny turbo (looks like a 0.3 ar)
maybe 150ish but i do plan on getting a bigger turbo in the distant future.
http://i57.tinypic.com/kykk4.jpg
http://i59.tinypic.com/140gcvm.jpg
http://i57.tinypic.com/qnshoi.jpg
http://i60.tinypic.com/29erog1.jpg
http://i59.tinypic.com/250nuvq.jpg

[Ryze268]

Looks good, keep us posted :)

[Bluevitz-rs]

looks like the turbo seals are shot. Hope you're doing a rebuild on it first.

[ipwnr]

is there any way of checking the seals without installing it? because i know the volvo that it was on had a bad pcv.

[CTScott]

is there any way of checking the seals without installing it? because i know the volvo that it was on had a bad pcv.

You can pressure test it off the car. I would test it to at least 80 psi. The easiest way to do so is with air. Plug one of the oil ports and charge the other. I built a rig for pressure testing things that has a quick disconnect air fitting, then a ball valve, then a 3 way T with a pressure gauge on the second leg and the connection to what I want to test on the third. attach it to the device, connect it to the air compressor and charge it to the desired pressure, then close the ball valve and watch the gauge. If it starts to drop, then you have a leak.

[ipwnr]

thanks for the tip. i hooked it up to a little 12v tire pump and i started hearing a hissing noise at around 5psi:/ so i guess i got to rebuild it. i might try an ebay rebuild kit.

[Bluevitz-rs]

Was the air coming out of one of the turbines? Also is there any shaft play?

[ipwnr]

yes the air was coming out of the compressor side and there is a bit of shaft play

[Bluevitz-rs]

It's definitely something to put on the 'to do' list then.

[ipwnr]

well after driving around and hearing a clunk on every bump i found out that my rr shock was blown :/ good thing i have a parts car.

http://i59.tinypic.com/10wva7l.jpg
http://i61.tinypic.com/9r0z28.jpg

[Bluevitz-rs]

That sucks. Luckily they're really easy to change.

[ipwnr]

yeah real easy. the last echo i did it on took 5 min and i didn't even need to jack the car up

[Ryze268]

Any updates?

[ipwnr]

getting the replacement shock from the parts car but otherwise nothing new. this will probably be a slow build since im still in high school and its not my no.1 priority but i will still post updates if i get any new parts.

[ipwnr]

here is a little update on the turbo.

got the turbine housing off with a hammer and chisel
http://i60.tinypic.com/2j4ub10.jpg

compressor wheel came off with ease
http://i59.tinypic.com/hrakok.jpg

turbine side bearing has score marks on the outside O.o
http://i62.tinypic.com/iof1x0.jpg

could not get this circlip off so i stoped here for now
http://i59.tinypic.com/2he9fgz.jpg

[Bluevitz-rs]

Needle nose pliers won't fit?


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[ipwnr]

ok i got the little circlip out and got the the rest of the turbo apart.
http://i61.tinypic.com/2dt26wz.jpg

http://i59.tinypic.com/2mzcmlj.jpg

http://i57.tinypic.com/315fsx5.jpg

http://i62.tinypic.com/ztdra0.jpg

http://i58.tinypic.com/2s6lf9e.jpg

http://i59.tinypic.com/a2fcdf.jpg

[Bluevitz-rs]

That is one cooked turbo. Hopefully you can clean it all up and rebuild it.

[Bluevitz-rs]

any progress?

[ipwnr]

yes i just recently did a compression test and here are the numbers

1:195psi
2:210psi
3:220psi
4:220psi
reason i did the compression test was to confirm a bent valve (there was a very noticeable tapping afterwards) due to a miss shift on the highway from 3->2 instead of 3->4. i would like to hear opinions if its worth rebuilding this engine or just buying a junk yard engine or maybe just a new head if the pistons and walls look good.

[Bluevitz-rs]

I'm kinda in the same boat. Only that happened to the engine when it only had 30k km on it. Dealer replaced 3 valves in cyl 2 and 3 and now with 160k km it has lower compression on those cylinders. So I got a used head and am rebuilding it. Only difference is I have a brand new short block to put it on. So I'm building a mild turbo system to run on it too.

[ipwnr]

well i settled on getting a cylinder head from the junk yard when its $50 parts day, other then the head gasket what else would i need? and also how difficult is it to remove the head while the engine is still in the car?

[Bluevitz-rs]

It is VERY involved. I worked on one out of the car and it took me an hour and a quarter with my portable impact gun.

[ipwnr]

I do realize how involved it is and it would be a great learning experience as this car to me is a project car.

[ipwnr]

the fic just arrived in the mail and its time to install :)
it came with a pnp harness for a 91-94 nsx that i will not be using lol.

http://i61.tinypic.com/f9dvua.jpg

[ipwnr]

little update i got the fic installed but im having issues with it. one of the issues is when i intercept the maf the fic reads and sends too high of a voltage and makes the car run super rich so for now i just have the maf taped and the car runs ok. the second issue im having is the throttle position sensor shows 0% all the time on the fic. and one more the map sensor is reading 10 psia instead of around 2-3 psia wich was what i was expecting.

[Bluevitz-rs]

I think you have to make sure all the maf maps are zeroed out. The other issues I don't know. Sounds like a wiring issue.

I don't have an FIC. I'm just basing my knowledge from what I've read over the years.


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