UPDATE
Got it all together and to the dyno and what was to be a long day.
Previous tune was with BP 98 and made 268whp. I figured we'd be making north of this with the much larger cooler and more boost. We struggled raising boost from the existing 16psi due to the ignition breaking up and could only manage 246whp.
We moved onto an ethanol tune and picked up 56whp at the same 16psi boost and then onto 319whp at 20psi. Part way through the ethanol tune Mr Tunes came and got me and was talking about the exhaust smoking. Arh crap. I walking into a dyno booth with my car smoking like Cheech and Chong. It only happened once then and once after I got it home and until now. We pulled the plugs and they looked as expected. Did a comp test and with all looking good we thought the turbo might be the next thing to check out but would continue the tuning and see what happened. The rest of the night (until 23.30) was uneventful.
From here I got the car home and went to the QLD track day. I had the Cheech moment once more there but otherwise found that while on the dyno the car was ok the amount of engine movement in the real world was much greater and I had an issue with an IC pipe coming off. Other than this it was good, the thing is fast! I really like the way it delivers power and is fantastic between corners in the midrange and not too far from what I think is perfect for a street car.
I only really took Eric for a spin before it started to make an odd sound like a pressure leak, was running lean and the ignition unhappy and bucking badly. This had me digging and I figured it was related to the smoking issue. I did another intake pressure test and it became evident that I'd solved the pipe issue with it happily holding 30psi. Then I thought while I had 1/8th of a tank I replaced the pump hanger and maybe the pump was higher than before so I put 20L into it and took it for a drive. This fixed the running lean issue so I'll need to lower the pump next time the tank is out. However the ignition issue was still there so I moved onto inspecting that.
Plugs looked great (I also did a leak down while to plugs were out and it was good) so I moved onto the cap n rotor as I knew my ignition system could be prone to eating rotors and found my first surprise. As I removed one of the leads it was sticky and difficult to remove and i found a mess on the lead end and cap terminal. I guess it's corrosion of sorts but was kinda like somehow some chewing gum had made its was in there. I got a new rotor and cap onto it and had my lead guy put a new end the the ign lead. This changed to car! It was so much more responsive than before and the ignition issue was gone but the odd sound was still there and the exhaust was smokey, only slightly but definitely smelt like oil was burning so I decided to check turbo bearing play and started to remove the turbo.
This is when I found another surprise and the cause of the odd sound. The bolts holding my turbo adapter to manifold had backed out. By this time the cooling system was drained and the lines all removed and with the smoking issue I continued to remove the turbo for measurement and confirmation the shaft play was out of spec. The thing also sounded like the bearings were rolling in grit.
I think the cause of this was due to my install. I mounted the CHRA with the water port horizontal and with both water lines coming in from the underside of the turbo. The new set up has it with Garretts recommended mounting angle with the supply low and exit higher to promote thermal siphoning. I've got a GTX2867r as a replacement and am in the process of installing this. I'm kinda excited that I've found the few issues that could be part of the reason for the dyno issues and I'm looking forwards to some more tuning.
post edited by 5SGTE - 2017/11/17 21:40:53