Topic: turbo 2.5 tj project need advice on odds n ends

[GPSAR TJ]

Ive been compiling parts for a while as time allows between work and holidays. motor will be rebuilt shortly (stock nothing fancy) and I will be setting up making the exhaust, mounts ect while its on the stand in the semi warm garage.    So...... heres what I have. 2 decent size  intercoolers to choose from (11"x23'' in one side out the other ,and a smaller 7"x22" with in and outlet on the same side). one very good condition garret t3/t4 turbo w flanges and gaskets but no oil supply or drain line stuff. plenty of material for exhaust, a ton of pre bent intercooler hoses and rubber couplers and clamps (more than i will need) a fairly cheap chineese blowoff valve, an ebay 16lb external wastegate with flanges gaskets ect but this is no good to me unless there is some way to adjust it reliably to work at 6-7 psi (buddy had layin around so if its free its for me) 4 mustang svo 36# injectors. so I need a wastegate, Ive seen some cheapo 4-7 lb adj units and may go that route. I need to get oil in and out so ebay again for a complete kit with weld in bung for the oil pan and fittings/ flanges for supply side. fuel management is the confusing part, my tank is tucked up 3 inches and I have a panel built into the floor of the tub to access the top so can I replace the pump with a diffrent unit or a piggyback type in tank setup. FMU, what kind, what brand, what ratio ?? how about fuel pressure reg?  I intend to retard the baseline timing 4 to 5 deg. via shifting the crank pos. sensor location. and Im doin the check valve on the map sensor.  im shooting for 5-7 lbs . the wastegate is high on my priority list and I wanna get that sorted out so i can start fabricating the exhaust. Any advice ? anything on the list sound like a bad idea? thanks, Jason

[sharpxmen]

Ive been compiling parts for a while as time allows between work and holidays. motor will be rebuilt shortly (stock nothing fancy) and I will be setting up making the exhaust, mounts ect while its on the stand in the semi warm garage.    So...... heres what I have. 2 decent size  intercoolers to choose from (11"x23'' in one side out the other ,and a smaller 7"x22" with in and outlet on the same side). one very good condition garret t3/t4 turbo w flanges and gaskets but no oil supply or drain line stuff. plenty of material for exhaust, a ton of pre bent intercooler hoses and rubber couplers and clamps (more than i will need) a fairly cheap chineese blowoff valve, an ebay 16lb external wastegate with flanges gaskets ect but this is no good to me unless there is some way to adjust it reliably to work at 6-7 psi (buddy had layin around so if its free its for me) 4 mustang svo 36# injectors. so I need a wastegate, Ive seen some cheapo 4-7 lb adj units and may go that route. I need to get oil in and out so ebay again for a complete kit with weld in bung for the oil pan and fittings/ flanges for supply side. fuel management is the confusing part, my tank is tucked up 3 inches and I have a panel built into the floor of the tub to access the top so can I replace the pump with a diffrent unit or a piggyback type in tank setup. FMU, what kind, what brand, what ratio ?? how about fuel pressure reg?  I intend to retard the baseline timing 4 to 5 deg. via shifting the crank pos. sensor location. and Im doin the check valve on the map sensor.  im shooting for 5-7 lbs . the wastegate is high on my priority list and I wanna get that sorted out so i can start fabricating the exhaust. Any advice ? anything on the list sound like a bad idea? thanks, Jason

you'll have some challenges with your plan, one thing i wouldn't do is to retard the timing as you describe, won't work for when you're not in boost. What you want or need is a boost timing retard that kicks in when your turbo starts to make boost and it is also increasing based on that. At 1 or maybe even 2 psi you should be fine with no timing retard given that you run higher octane gas and that you use colder spark plugs.

FMU I don't know how would work on the Jeep but before you can use it you'll need to modify your fuel return since it's at the tank, don't really have any advise here.

[st.chevrolet]

I agree with Sharp! And before you start modifying your fuel system, try the Hesco "Fuel Management Unit # HESTJFMU",  it has everything you require except larger injectors. I have not used one but have been advised by others who have turboed their TJ 2.5's,  that they respond quite well with this setup and larger injectors.
Heres the link:

http://www.hesco.us/shop.asp?action=details&inventoryID=59157&catId=7974

[sharpxmen]

one other thing (forgot to mention the first time) - if you keep your base pressure at 49psi and add an FMU (or even the Hesco unit) your 36# injectors would be too much for 7 psi boost (if you end up higher than the 49psi fuel pressure) so going this route might require either rethinking the size of the injectors to match the flow you need at that boost level.

good point on the Hesco, that's a great solution without having to add a return line and mess with the fuel system.

[Torch_Ind]

would you not need any computer tuning?

[sharpxmen]

would you not need any computer tuning?

different way to achieve the same result (get the AFR to where it needs to be in boost). Ideally should have both and a way to alter the O2 output for closed loop operation when in boost.

[GPSAR TJ]

 a little update... got a handfull wastegate springs from 3 to 7.25 range (4 of em from similarly afflicted turbojdm neighbor) got my boost and af ratio guages. had the intercooler dunked to check for leaks(good to go) the motor kit arrived so i can put that together. still gotta get the oiling kit for the turbo. If I spend 625 on the hesco unit I will be living in the garage on a permanent basis so I need another option. can I use a booster pump and fmu with a return going back to the low pressure side, If so could you reccomend a pump (checked out walbro but im not sure what pump i need)  Also...Injectors, what # should I be using, thought I struck gold in my neighbors garage when I found those svo units all shiny n new.  theres so much stuff on yj turbos but limited info on 2.5 tjs so sifting thru all the info is confusing and info on most tj applications is incomplete. so far ive got less than 500 into turbo related stuff, alot of freebies from buddies, crap laying around the garage ect. so i feel im ahead of the game( cant really count the motor rebuild kit or machining as that was a pre-existing condition) 
so...will a piggyback pump to fmu with return to the low pressure side do.?                                                  And.....what size injectors do i need ?                                                                                                                                                Its warming up finally, days are getting longer and ive missed waay too many good wheelin trips or spent them in the passenger seat . Thanks for all youre help so far, very much appreciated.                                                 

[sharpxmen]

a little update... got a handfull wastegate springs from 3 to 7.25 range (4 of em from similarly afflicted turbojdm neighbor) got my boost and af ratio guages. had the intercooler dunked to check for leaks(good to go) the motor kit arrived so i can put that together. still gotta get the oiling kit for the turbo. If I spend 625 on the hesco unit I will be living in the garage on a permanent basis so I need another option. can I use a booster pump and fmu with a return going back to the low pressure side, If so could you reccomend a pump (checked out walbro but im not sure what pump i need)  Also...Injectors, what # should I be using, thought I struck gold in my neighbors garage when I found those svo units all shiny n new.  theres so much stuff on yj turbos but limited info on 2.5 tjs so sifting thru all the info is confusing and info on most tj applications is incomplete. so far ive got less than 500 into turbo related stuff, alot of freebies from buddies, crap laying around the garage ect. so i feel im ahead of the game( cant really count the motor rebuild kit or machining as that was a pre-existing condition)  
so...will a piggyback pump to fmu with return to the low pressure side do.?                                                  And.....what size injectors do i need ?                                                                                                                                                Its warming up finally, days are getting longer and ive missed waay too many good wheelin trips or spent them in the passenger seat . Thanks for all youre help so far, very much appreciated.                                                

should work, basically you'll be making your own hesco unit, but you'll have a bit of testing to do. one problem is that you can't reduce pressure, just increase it (EDIT: i mean that your minimum injector rail pressure would be 49psi). For injectors start with those ones and see how it goes, they will be large for no boost but I'm not sure how much your PCM can compensate for the extra flow so you'll have to test and see as well.

what O2 gauge did you get? is it a wideband?

[GPSAR TJ]

expecting a lengthy tuning process, its a elcheapo autometer, not a wideband...but i may be able to get one as a long term loaner from a buddies never ending project car. eventually Ill have to give it back

[Steve97tj]

Did you ever solve all of your issues? Have any videos or feedback?