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Want to turbocharge your 1.6?

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saqmaster

Post subject: Want to turbocharge your 1.6?

Posted: Tue Apr 03, 2007 8:15 pm

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I've been doing a little thinking recently and i'm curious to find out how achieveable it would be to turbocharge the 1.6 zetec to give approx 25-30% more power (but with torque to die for) for absolute minimal outlay..

The only modification would be to bolt the turbo on to a completely standard engine, get the exhaust modified, sort out the turbo oil feed/drain and get pipework made to go from the turbo to the throttle body (perhaps use an escort turbo crossover and some universal parts)..

Then the turbo would be set up to only producea few pounds of boost, maybe up to 5 psi.. should take a 90PS 1.6 up to 130bhp or so, but with a good amount of torque and all the right noises.. it'd have to run on 99RON fuel.. it'd involve a fair amount of time and development from me with regards to the tuning/mapping (of the original ecu in the car) to get it right..

This is just a bit of fun development for me and if it works out, I might offer it as a simple conversion for the future..

So, the question is, does anyone have a car that they'd like to try this on? Basically i'd guide you on what parts you need, how to get them fitted, etc. then I would remap the car to suit.. at zero cost to you of course.. there is of course a chance that at the engines standard high compression ratio that it just won't be able to sustain 5 psi or whatever reliably, which would then require a decompression plate or something to make it feasible, but without the testing you just don't know..

Before you say "yeah but 2 litre mondeo engines are 130bhp".. yes they are, but they wouldn't have the torque of the turbo engine.. ultimately a 130bhp turbo engine is going to be faster than a 130bhp non-turbo engine..

I'd prefer to do this on a 1.6 ideally, as there is the most scope for noticeable performance gain.. but I am willing to do the development on 1.8's and 2.0's too.. the constraints though are that the standard fuel injectors aren't going to handle more than about 130-140bhp, which pretty much means a lot more work on 1.8-2.0 engines as they're near this power anyway.. i'm just trying to think of a real simple, almost bolt-on package.. it might not even need an intercooler, however it would enable more boost to be run..

Let me know if you're interested, or if you have any questions.. you're probably looking at approx. ÃƒÆ’Ã¢â‚¬Å¡Ãƒâ€šÃ‚Â£500 for a turbo manifold, turbo, exhaust modifications and some pipework.. but i'd budget ÃƒÆ’Ã¢â‚¬Å¡Ãƒâ€šÃ‚Â£1k max as those always-required little extra bits and bobs quickly add up!

Thanks,
Stu

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EvilDes

Post subject:

Posted: Wed Apr 04, 2007 7:48 am

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saqmaster

Post subject:

Posted: Wed Apr 04, 2007 8:22 am

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Don't get me wrong, I know exactly how to turbocharge the 1.6 'properly', i'm just trying to find out what the limit is with regards to literally a bolt-on and a chip..

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onslack

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Posted: Wed Apr 04, 2007 8:26 am

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i dont mind being a candiate for the 2.0 turbo conversion if you have any[wink]

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saqmaster

Post subject:

Posted: Wed Apr 04, 2007 8:30 am

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Hm yeah but the real goal here is to see what is possible from the standard 1.6 running gear.. I need to flow check the 1.6 injectors to see just what is possible..

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onslack

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Posted: Wed Apr 04, 2007 8:38 am

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i reckon this could open up a few doors for people that have wanted to turbo thier 1.6's but have been knocked back and told to 2.0 it instead

keep us updated, hopefully you'll find a suitable candidate for the 1.6 turbo conversion

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jdfiesta

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Posted: Wed Apr 04, 2007 9:26 am

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does sound like a good idea. but would the 1.6 head flow the required amounts for 130-140bhp?

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saqmaster

Post subject:

Posted: Wed Apr 04, 2007 9:35 am

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onslack- it's always been an option to turbocharge the 1.6.. it'd cost the same as to turbocharge a 2.0 though, if done thoroughly.. the purpose of this, which perhaps i'm not explaining properly, is to offer a real simple bolt-on low boost upgrade to give the car a noticeable edge.. it should be faster than a 2 litre n/a too..

jdfiesta- oh yeah, definatelyl, you could most likely get 200bhp from that head in turbocharged form..

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jdfiesta

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Posted: Wed Apr 04, 2007 9:38 am

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good luck with it dude.

what means you gonna use for measuring the load of the engine?

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saqmaster

Post subject:

Posted: Wed Apr 04, 2007 9:41 am

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onslack

Post subject:

Posted: Wed Apr 04, 2007 9:42 am

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saqmaster

Post subject:

Posted: Wed Apr 04, 2007 9:44 am

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yeah, that's my thinking behind it.. i can do 300+ bhp 2 litre zetec turbos all day long, but that's a big outlay and more than some people want.. i need to do a lot of investigation first to see if this is remotely possible (ie, is the maf big enough on the 1.6 to meter 140bhp worth of air, can the injectors supply that much fuel).. if it's not possible with the 1.6 parts, i probably won't bother as swapping lots of bits around requires extensive remapping which would never be as-good as the original ford mapping.. it'd be better just to do a complete conversion with new management etc..

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jdfiesta

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Posted: Wed Apr 04, 2007 9:47 am

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that was supposed to say load on the engine. ie, MAF or MAP but last post answered that [lol]

would using the 2.0 MAF not be a feasable option

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saqmaster

Post subject:

Posted: Wed Apr 04, 2007 9:49 am

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onslack

Post subject:

Posted: Wed Apr 04, 2007 9:50 am

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Mattyboy Esq

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Posted: Wed Apr 04, 2007 10:10 am

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You can turbo charge my 1.6!

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fiestafletch

Post subject:

Posted: Wed Apr 04, 2007 10:51 am

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if I had a ÃƒÆ’Ã¢â‚¬Å¡Ãƒâ€šÃ‚Â£1000 id be well up for that! unfortunately im skint as fook lol

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saqmaster

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Posted: Wed Apr 04, 2007 12:53 pm

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Okay.. after doing some research.. The original 1.6 MAF will not be up to the job for this conversion.. It is only capable of measuring up to about 100bhp worth of air.. so changing this for a 2.0 MAF will definately be on the cards (with me suitably recalibrating the ecu/chip for it, along with all the other remapping).. oh well, nice to know!

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lucasdemoley

Post subject:

Posted: Wed Apr 04, 2007 8:07 pm

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Joined: Sat Mar 12, 2005 1:49 am
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A bit brave. I would say just stick a 2.0 in there to someone asking generaly, but I get where you are coming from and what you are hoping to achieve.

I really dont think the si could sustain even a couple of psi without some sort of decompression plate or something, but if you dont try you'll never know, but defo have some sort of knock sensor rigged up to avoid damage.

Also, the head would have to be machined to get the frst exhaust manifold, if that is the one that will most likely be used, to fit.

Quite a few hurdles but should be interesting.

You could try it yourself with like a ÃƒÆ’Ã¢â‚¬Å¡Ãƒâ€šÃ‚Â£100 si on ebay or something, if there arnt any willing individuals!

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saqmaster

Post subject:

Posted: Wed Apr 04, 2007 8:09 pm

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I've got a fair idea of where the det-limit will be with the engine, i've got a fair amount of experience with turbocharging zetecs. I always monitor for det (knock) when mapping, you don't have to worry!

You don't have to drill the head to use a FRST manifold. Not necessarily. Perhaps i'll get some adapter plates made up. I'm not decided yet!

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