89 Trooper 2.6 4ZE1 Turbo build.

5878 Views 105 Replies 18 Participants Last post by MrDunge, 7 d ago

MrDunge

Discussion Starter · 3 mo ago (Edited)

3

Well the manifold finally arrived. It looks great and there is less than 5mm deviation in the piping.

I'm gonna post the build as I can w build tips and info w pics.

So far the block is done. Bored 20 over magnafluxed and cleaned, Jerry sent me a set of his last 20 over high compression pistons. Had the crank polished and balanced.

550cc injectors are gonna be used w a 255 gph fuel pump. Jerry Cam. I had to modify the fuel rail and intake holes slightly bit otherwise they fit well.

Max speed pros oil and water cooled turbo set to 10psi initially. Blow off valve set at 12psi.

Front intercooler, electric fans w thermostatic control.

AEM Air fuel mixture monitoring kit.

I'll post the parts list later for those who are interested. As for now here's a few pics of the manifold.

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61 - 80 of 106 Posts

wPine

· #61 · 2 mo ago

MrDunge said:
I have repaired that radiator like 3 times already. It's like 10 years old. I'm gonna replace it. It was holding on like my hopes and dreams. Lol

I bought a CSF from rockauto and I couldn't be more impressed with the quality.

Reactions: 1

MrDunge

Discussion Starter · #62 · 2 mo ago

wPine said:
I bought a CSF from rockauto and I couldn't be more impressed with the quality.

yep i got that one just now lol

MrDunge

Discussion Starter · #63 · 2 mo ago

So after talking to a few people including Billie Rice I have decided to go w a stock injector however using the ones for the 96 and above 2.6 applications. These are around 350cc. Hes seeing around 14/1 air fuel at idle and as low as 11 or 12 at WOT which is about a perfect as you can expect. At 90% duty cycle I can still run around 10 psi boost before I can expect it to run lean at WOT.

I am planning on the switch this weekend I will update once completed

Reactions: 2

redcentinela

· #64 · 2 mo ago

MrDunge said:
So after talking to a few people including Billie Rice I have decided to go w a stock injector however using the ones for the 96 and above 2.6 applications. These are around 350cc. Hes seeing around 14/1 air fuel at idle and as low as 11 or 12 at WOT which is about a perfect as you can expect. At 90% duty cycle I can still run around 10 psi boost before I can expect it to run lean at WOT.

I am planning on the switch this weekend I will update once completed

Nice numbers. What type of fuel management are you using ? I also have a Turbo Trooper, running stock injectors.

MrDunge

Discussion Starter · #65 · 2 mo ago

redcentinela said:
Nice numbers. What type of fuel management are you using ? I also have a Turbo Trooper, running stock injectors.

I know, you are actually one of the people I read up on in reference to info on my decision lol. Thanks for letting me lurk!

So I am using a AEM a/f monitor system in the exhaust and a adjustable FPR. The computer is so dumb that it doesnt trim fuel in any way. So I treat it like a carb, let it run adjust fuel pressure until the numbers are good and let it eat lol

Reactions: 1

redcentinela

· #66 · 2 mo ago

MrDunge said:
I know, you are actually one of the people I read up on in reference to info on my decision lol. Thanks for letting me lurk!

So I am using a AEM a/f monitor system in the exhaust and a adjustable FPR. The computer is so dumb that it doesnt trim fuel in any way. So I treat it like a carb, let it run adjust fuel pressure until the numbers are good and let it eat lol

So, the only fuel management you are using is a fuel pressure regulator , no FMU ? I don’t have an adjustable fuel pressure regulator, just the FMU.

Can you take a picture of it ?

MrDunge

Discussion Starter · #67 · 2 mo ago

redcentinela said:
So, the only fuel management you are using is a fuel pressure regulator , no FMU ? I don’t have an adjustable fuel pressure regulator, just the FMU.

Can you take a picture of it ?

No im not using a fmu. A couple others aren't either, just the process I listed above.

It's not a good pic you'll have to wait til this weekend when I get back on it for a different one. It has a gauge on the side to show you the pressure. It has a allen key adjuster on the top w a lock nut for adjustment. While it's running(it's the only way to get a accurate reading) adjust fuel pressure up or down til you get a a/f mix that's as close to 14 at idle as you can. Since it's a vacuum controlled unit it will automatically increase fuel and pressure under load and give you the 10 to 12 number you need under boost.

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redcentinela

· #68 · 2 mo ago

What Automotive fuel pressure regulator are you using ?

MrDunge

Discussion Starter · #69 · 2 mo ago

redcentinela said:
What Automotive fuel pressure regulator are you using ?

www.amazon.com

Amazon.com: Universal Adjustable Fuel Pressure Regulator Kit Aluminum Gas Oil Injection Pressure Regulator with 0-140 PSI Gauge, AN6-6AN Fuel Line Hoses, Install Tool Accessories (Black) : Automotive

Buy Universal Adjustable Fuel Pressure Regulator Kit Aluminum Gas Oil Injection Pressure Regulator with 0-140 PSI Gauge, AN6-6AN Fuel Line Hoses, Install Tool Accessories (Black): Pressure Regulators - Amazon.com ✓ FREE DELIVERY possible on eligible purchases

www.amazon.com

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MrDunge

Discussion Starter · #70 · 2 mo ago

3

ITS ALIVE! Sort of lol.
I got it running w the updated stock injectors this weekend. But alas now the steel power steering pressure line is leaking. I got a hydraulic guy who can fit it, but dang.

I put the heat shielding wrap on the lines that needed and some on the firewall. I'm happy w how it turned out. However wear gloves if you use it. Fiberglass makes you itchy.

I still need to dial in the fuel pressure and timing but I can't get a accurate af mix reading until I have more exhaust ran. The sensor is to close to the end of the pipe I have ran so the numbers are skewed.

Pretzel got me a center console and e brake lever out a rodeo this weekend at a pick and pull and imma see if it'll work in the trooper. I'm planning on eliminating the t style under the dash to the between the seat style. I'll make a new thread for that if it will work.

Only 17 days till uwharrie......idk if I'll make it......

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MrDunge

Discussion Starter · #71 · 2 mo ago

A good news update!
It runs! I drove it around a little this weekend. The spark plugs I got need to be swapped, they are to "cold" and its hard to start, I ordered a "hotter" set and will install today. Its running at little rich even if I turn the fuel pressure down. Hopefully this hotter plug will resolve the incomplete burn.

Its running 5 to 7psi under 4k rpm and 10 to 12 psi over 5k to redline. I am gonna keep it this way til I get it through the break in period and change the break in oil to regular oil. I may have a small charge pipe leak somewhere, I am gonna recheck all the clamps after work today since I ran out of time Saturday. I need to adjust the blow off valve as well, its releasing at to high a pressure.

All the gauges are wired up and working, didnt get pics yet tho.

Its going to the exhaust shop this week, I am gonna run a quieter exhaust, I wanna hear the engine and turbo until I feel like nothing is gonna come apart. After that I may get a louder muffler but at my age I enjoy the quiet more and more lol. I am gonna run 2.5in exhaust all the way front to back.

I am conflicted about going to Uwharrie, I got alot of time and money in this build and its 250 miles one way......Do I go and either not wheel or go the easy trails, or do I wait til the fall run to make sure I have time to put miles on the engine and tweak what needs to be tweaked to make sure its 100% right. I need it drive it, but I dont wanna be 4 hours from home if something goes wrong. Only 10 days til we are supposed to go and I am totally on the fence.

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turnerd

· #72 · 2 mo ago

I'm curious, what plugs did you get?

Can you really feel the boost kick in? The 2.6 is a screamer above 4k, so I can't imagine what it's like with a turbo at 5k. Can't wait to see pics and videos

MrDunge

Discussion Starter · #73 · 2 mo ago

turnerd said:
I'm curious, what plugs did you get?

Can you really feel the boost kick in? The 2.6 is a screamer above 4k, so I can't imagine what it's like with a turbo at 5k. Can't wait to see pics and videos

So I used a champion 7345. I spoke to Jerry about it. I wanted to start w a cooler plug since I'm running 93 octane and boost. He said that is the plug used in 2nd gens troopers. But I may run into it being too cold since those engines use a coil over plug design and have a much higher voltage than the distributor setup the 1st gens have. He was (as always) right lol.

I have a set of NGK 7082 plugs I got in today and will install after work. We shall see.

Thankfully the turbo I used boosts gradually. There is a lag but it's a build up lag. It pulls hard though. It's how I wanted it. Again this is more setup for highway speed power and power under load for pulling a trailer. It's not for out the hole speed. So 2k to 4k rpm 5 to 7psi is perfect. I'll dial it up later.

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wPine

· #74 · 2 mo ago

Did new spark plugs help?

MrDunge

Discussion Starter · #75 · 2 mo ago

wPine said:
Did new spark plugs help?

They did, the ones I took out were all black and smelled like fuel.

However I have a new issue now.....getting a code 61 for mass air flow......swapped it w one I know works. Still popping code. And when it pops the code there is a click under the hood and it starts to run like dog poo. I think I may have a broken wire in the lead that runs to the sensor. I ran out of time last night so if i have time tonight imma check it out. I also need to call Jerry and find out what that click is. Something is switching which is changing something fuel or air wise.

Anyone know what that could be.

MrDunge

Discussion Starter · #76 · 2 mo ago

Well after fooling around last night w it i found the culprit of the 61,35, and other codes......the stupid coolant temp sensor to the ecu came unplugged.....seriously. Plugged it back in and all the codes went away check engine light went out, fuel mix was correct and it ran like a dream!

Drove it 12 miles to drop it off for exhaust to be ran and damn it runs so good! Still have the turbo dialed down to 5 to 7 psi under load and with no exhaust running 14 a/f under load. Wants to cut off at idle after i come to a stop from cruising speed but again no back pressure and thats a minor adjustment.

Its a different truck for sure, so much low end power even w low boost. once the exhaust is done I plan on driving it to Tonka toys house for a break in drive about 60 miles one way. If all goes right then I am gonna make the Uwharrie run!

I will get more pics soon, however this site doesnt allow vids.

Reactions: 5

turnerd

· #77 · 2 mo ago

You can post the videos on youtube and link them here if you feel so inclined

Enemigo

· #78 · 2 mo ago

Take it to the drag strip. Get some wheeling videos.

Back in college I built a turbo 1990 Acura Integra. I ran a T3/T4 turbo with intercooler and "7 psi" of boost. I quote "7 psi" because that was the plan, and I got a wastegate with two springs. 7 psi was like a slightly healthier motor, basically what it would have felt like at sea level. But the other spring was 15 psi and it would spike to like 17 psi. At 2,550 lbs it was a total screamer. I blew rings racing an Audi running up into the mountains on I-70. When I went to swap motors, it would still spin the tires from a roll in 3rd gear. Once I got around to tuning it, it put 277 whp. That car was awesome and I've wanted to build another turbo car ever since. Especially now that I have way more tools, experience, and could weld if I need to. Oh yeah, the replacement motor I bought was crap and I returned it and just sold the kit and car. I still miss it. It was a total sleeper.

All that to say that I've been watching this thread closely and love it. Well done!

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MrDunge

Discussion Starter · #79 · 2 mo ago

Enemigo said:
Take it to the drag strip. Get some wheeling videos.

Back in college I built a turbo 1990 Acura Integra. I ran a T3/T4 turbo with intercooler and "7 psi" of boost. I quote "7 psi" because that was the plan, and I got a wastegate with two springs. 7 psi was like a slightly healthier motor, basically what it would have felt like at sea level. But the other spring was 15 psi and it would spike to like 17 psi. At 2,550 lbs it was a total screamer. I blew rings racing an Audi running up into the mountains on I-70. When I went to swap motors, it would still spin the tires from a roll in 3rd gear. Once I got around to tuning it, it put 277 whp. That car was awesome and I've wanted to build another turbo car ever since. Especially now that I have way more tools, experience, and could weld if I need to. Oh yeah, the replacement motor I bought was crap and I returned it and just sold the kit and car. I still miss it. It was a total sleeper.

All that to say that I've been watching this thread closely and love it. Well done!

Thanks I really appreciate it! I have a 2017 turbo mustang that I also love.......thats my go fast sleeper, all the badges removed, quiet exhaust. Love it lol. Over 400 whp.

Wheeling vids will come soon, uwharrie is next week so yea. I am gonna have it dyno'd at a buddies shop as soon as I get time to head a hr one way to his place. Supposed to pic it up from the exhaust shop today.

wPine

· #80 · 2 mo ago

So excited to see it at Uwharrie!

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