2.4 JTD FMIC project - tips

Do you go to any of the AO meets in the Derby area?

pICS

K&N is located where old intercooler was, with an excellent cold air flow through the air dam in the front bumper next to the fog light.

The FMIC sits well under the front bar.

The boost pipes are only laid loose in place for sizeing up at the mo.

The boost gauge matches colour when ignition is on as it is backlit like the others and turns more orange than the red as seen in the photo.

Pics of the pipe work from the turbo to the FMIC, this is all fixed in place with a gentle(r) bend than a harsh 90.

Good pics Jason - The intercooler looks old though? Was it from a scrappy?

Boost gauge looks sweet! Ever think you'll run higher than 2.0 bar though?

K & N fits in well there too, I have a BMC CDA myself.

Pic showing fairly straight air intake pipe to the cone filter, the wiring for the air mass reaches also!

Thats handy. How are your spool up times now since you've replaced it with a straight pipe?

The FMIC was off a saab 900 turbo I broke not so long ago.

It has the benifit of being black, and therefore 'not on show' as I prefer my cars to be sleepers.
It is a few years old, but I had it, and it has entry & exit pipes on the same side.
Certainly not the biggest or most efficiant IC, but this is more about breathing - getting rid of those restrictions such as 90degree bends.

Most of the charge cooling will be done by the water injection which is directly into the boost pipe just after the intercooler.

Is it safe to send water through into the engine though? Water doesn't compress remember, or will it be steam already once its in the engine?

The boost gauge reveals all, whilst spool up is better as the whole thing will breath a whole lot easier, full boost is not reached until nearly 2.5k rpm.
I cannot talk for this project, rather project 1 - same year/type of car, but bigger FMIC

I only ran 1.5bar boost (20/21psi) on project 1 as I never got to take it back to Red Dot for tuning.

Red Dot reckon 2 bar is fine for these, which is at the end of the gauge!

The led on the bottom of the boost gauge lights up when the water/methanol system is active, I can adjust when this comes in, typically 1 bar, but I may set higher depending on what boost I finally decide to run.

Water injection,

it injects as a fine mist at around 165psi through a really fine nozzle, so it atomises into the air intake.
On compression it turns to steam and cools the exhaust gas temperatures by a couple of hundred degrees, thus allowing safer running of higher boost levels.

The methanol mix is for its high octane rating (a bit like race fuel), so simply adds more torque and in turn power.

Water injection is nothing new, they used it in WW2 air craft.

Also steam cleans the inside of the engine!

but it is not good to inject before either the turbo or intercooler.

Have you heard about LPG injection too Jason? I looked into it a while ago but no companies could give me any figures for performance or how it would work without reducing the diesel fuelling.

reducing the diesel fuelling is easy to do by remapping.

But I thought it was illegal in the UK?

But I have heard it give fantastic results.

Sounds like one of those things you have to research abroad, maybe US? A bit like I did when I imported the water injection! - They wanted 3 times the amount for a so called UK kit!

Jason do you have any pictures of the water injection system?

Originally Posted by kgb

Jason do you have any pictures of the water injection system?

Started that last night by locating the pump, I will take pics and post as it progresses.

I appreciate that Jason

Will wait for the pictures.

Originally Posted by jasons

Red Dot reckon 2 bar is fine for these, which is at the end of the gauge!

I'm running 1.9 Bar at the moment - no real worries, except it finds any weaknesses in the existing hoses & rips them apart. 2 new hoses on order for me

yes paddy,

same problem, the standard hoses tend to split, the one from the turbo to the IC.

On a different note, the bumper needed a very slight trim when put back but a little cutting of the black mesh as both ends of the IC protrude through this, not noticable really as the FMIC is black as well as the mesh.

Current project now is the gearbox, looking to retro fit a 6 speed from a V6, ideally changing the 6th on the V6 for the JTD's 5th and change the final drive also, then mate it up to a Q2 LSD.

All theory at the moment, we have the 2 boxes, just need to find someone to change to cogs on them!