Modified 1kz build - new intake manifold setup

[surfee]

hey man how much for a dump pipe for my kzn185 1kte?

[Slydho]

Well as usual I can't leave anything along. I pulled my rear engine panel off to check up on how the dump pipe is holding up being as I've done about 2000k with it so far. No signs of any stress on welds etc. it did spit the gasket out so I've welded on a vband flange for simplicity.



I've been thinking about ditching the throttle body setup and trying to fix the poor design of the intake. Try get a more even air flow instead if it all being jammed down cylinder 3's throat. The next few pics explain my plan sorry about the quality of the 1 pic it was pitch black




I should have it all back up and running tomorrow. Along with an electric boost controller.

[tweake]

have you seen ARE's 1kz manifold ?

http://www.are.com.au/Inter/4x4%20Plennums.htm

[Slydho]

I have yes. They basically said it wasn't worth the trouble but if you can do yourself go nuts. but with my intercooler behind my this seemed the most logical way to do it. Front facing plenum style but back wards.

[Slydho]

She's alive again.

Marvel in her awesomeness!


I removed the throttle butterfly but to save some u just cleaned up the throttle body and mounted it back in its original spot to ensure the throttle cable and kick down lined back up.


The intercooler pipe is now a hole kit better. It runs 50mm of into a bell mouth trumped welded into the intercooler.





I took her for a short test drive. I'm a bit low on transfluid. But it is a lot more responsive. The boost gauge also flickers a lot more now due to the throttle body being removed. I'm not sure how the electric boost control is going to deal with it but we will find out tomorrow I guess

Cheers

[likemagic]

do you have a restrictor in the line to the boost gauge? Mine is a piece of plastic in the line with a 0.5mm hole in the line right next to the manifold, made a huge difference.

Maurice
KZN185, 1KZte waiting for mods

[tweake]

would the oil filter etc still fit if you made the main tube bigger. ie taper the manifold small front, large at the rear. shift the intake out a bit more.

[Slydho]

From my readings on ARE.com.au diesels don't need a large plenum. In fact the increase wouldn't be worth the effort.

[tweake]

its not the size itself that matters (ie wave tuning) but flow rates in each runner. need to get each runner equal.
it looks like your feeding 3 and 4 ok but 1 and 2 are somewhat restricted.

[Slydho]

No ways mate cylibder 1,2 get a much much more direct flow then before cylinder 3,4 will be about the same. These is not enough room to enlarge it and diesel Manifold design is not the same as on a petrol engine. Diesels are limited by fuel input where as on petrols they are limited by air input. All I wanted this intake to do is even out air distribution. Which it will have done.

[tweake]

...... It runs 50mm of into a bell mouth trumped welded into the intercooler.

The boost gauge also flickers a lot more now due to the throttle body being removed.

is that size right? you have 50mm diameter pipe for the intake?
if so its on the small side. the 2.4 2lt is 57mm. i would use at least 63mm.
it may explain the pulses your now reading.

not sure about the bell mouth. as the air flow is mostly flowing straight out rather than turning direction on all sides, a simple taper into the IC would work better.

[Slydho]

This isnt my first rodeo mate. I've thought long and hard on how it needs to be done. The manifoldS ID is pretty much 50mm so extending that the short distance to the intercooler makes perfect sence. As for bell mouth they are designed to promote larger air flow. Hence why they are used on intake manifold and turbo intakes etc. tapers take up room, Room I don't have.

All in all the flicker on the booet was only bad when u loaded it up with the brakes on. It's not bad driving round unless you got ya foot up it on full boost. I did about 100ks in it today and its a big change. Much more responsive! More boost on less throttle. It's just getting more and more fun to drive. Specially with the average of 570ks to a tank.

Next on the list is to make an stainless exhaust manifold with 38mm tial vband external watergate I have laying around. Im going to try make this equal length or as close to it as i can. This will mean a new dump pipe to. As well as a new water pump as mine is playing up.

[tweake]

fair enough if you don't have room.
surprised factory intake is only 50mm tho. smaller than a 2.4, sounds odd.
good to hear its an improvement tho.

[Slydho]

Gains are all we want

[KiwiOilBoiler]

Slydho, nice work so far, I like your 80/20 philosophy. I'm currently effing about with a Bighorn cored tmic on my KZN130 in an attempt to get my pre-turbo egt's down from a regular 730 celcius under any sort of load, (have seen 807!!!). EGT gauge gotta be best economy mod ever invented! Lots of backing off now that previously would have been pouring in fuel for no power benefit.

I see you have the two water? lines still connected to your tps plate, do these not serve to heat the charge on a std manifold, the reverse of what we are trying to achieve? Your thoughts appreciated.

Cheers, Adam.

[Slydho]

FMIC is a great idea. To be honest I didn't even look into what those do or where they come from or where they go. Being as the tb isn't used anymore I connected then back up as per factory as I couldn't be bothered investigating into it haha.