4.0 Remote Turbo Buildup

[rocket 5979]

Yes - This is what I have basically. A hobbs switch is connected to the intake and when it see's 1 LB of boost it turns on the pump that is connected to the PCV tract. When the pump turns on it vents to the air (does not go back into the intake); when it's off it goes into the intake like normal.

Whisper's...Psst...solenoid, not pump.

 

[CDW6212R]

Someone was on the Corral site selling used RV vacuum pumps. Most pumps would be overkill, unless there was a lack of normal vacuum. It's an important factor for boosted engines, some lower intakes have no PCV opening.

 

[frickea86]

Thanks for the explanations, I figured it had something to do with the added air volume or pressure. This thread has kicked off my push for doing more research on a turbo set for mine. Got a few things I want to do before then but I don't mine learning new things.

Funny thing is I just had my first splash of MIG welding on saturday, lol. My Fiancee's dad (old school ford man) was fixing their exhaust on their 98 expo. He had me practice welding on a few peices of scrap metal and then had me weld a few peices. I think I did an alright job, didn't ketch anything on fire.

 

[jah81592]

When boosting your engine, you start to get way more crank case pressure and blow-by. If you don't do anything about this, you can start to blow seals and such because of the pressure. Also, I've heard the rings will actually seat better without this pressure so I decided to eliminate this problem from the start with the STS PCV system.

"The system is designed so that when not in boost your PCV system will function as normal. When you get into boost then the hobbs switch will see it and close its circuit which will provide power to the PCV switch valve which will switch your PCV to a temporary vent-to-atmosphere system while under boost. Once you are off the gas and below 1 psi of boost then the hobbs switch will open the circuit and your PCV will go back to normal."

--- Rocket 5979

I am not overly excited about the STS PCV system. I have tuned several vehicles with it and it, well... just plain doesn't work. I still have mine operational but had to vent the cam cover because the STS pcv setup just wasn't enough. The same problem followed all the other vehicles-j

 

[CDW6212R]

So for that there wasn't enough flow potential for the crankcase pressure? I haven't made a decision, but I might look at the RV pump if it is small and quiet enough. An extra vacuum cannister may be helpful.

 

[rocket 5979]

I am not overly excited about the STS PCV system. I have tuned several vehicles with it and it, well... just plain doesn't work. I still have mine operational but had to vent the cam cover because the STS pcv setup just wasn't enough. The same problem followed all the other vehicles-j

I believe the biggest problem to be why the PCV bypass from STS doesn't work as well as it should to bypass enough gasses is due to that teeny tiny check valve that is included. It doesn't allow anything for flow. I believe if that check valve were swapped out to something that flows better then there would be much less problems.

 

[rocket 5979]

By the way (on the pipes I said I was going to plan B). I tried plan B and it didn't work out right, so I'm back to Plan A (Going into the passengers side of the intercooler from the turbo, and out the drivers side, up under the truck, and back into the engine bay to the TB. I found ALUMINUM (was using steel) cones to do the gradual transitions after a few days of searching. I’m doing the transition almost like rockets pics describe.

Plan B didn’t work out right because there is not much room under the truck for a 4” MAF and 3.5” pipe. I didn’t like the way it hung down.

I took one step forward, and two steps backwards; however, I'm on the right track now. I should have this all tied up by next weekend and will FINALLY mount the turbo.

Question. What check valve are we talking about?

It is a teeny tiny little brass piece about the size of your thumbnail. It slides into the PCV hose and will be the one-way check valve. I have already had two separate conversations with STS about redesigning this item as I believe it could be made in a better manner.

 

[CDW6212R]

I know what you mean Rob, I have dealt with worn out engines that had a lot of blowby. They will push out oil into the air cleaner, and blow out intake gaskets if they get too bad.

A PCV valve is a type of check valve, and some flow more than others in each direction. I wonder if a simple proper PCV valve could improve what you have James. I spent a little time at Pep Boys selecting a certain PCV valve to work on an old police Crown Vic that had tons of crankcase pressure.

 

[justin146]

Why do you need to run this check-valve. Won't the PVC valve block the boost from the crankcase?

Most PCV valves cant hold the pressure back. Mine leaked like crazy so I added a check valve right in front of it. You could use a PVC valve from a turbocharged vehicle though..

 

[jah81592]

I believe the biggest problem to be why the PCV bypass from STS doesn't work as well as it should to bypass enough gasses is due to that teeny tiny check valve that is included. It doesn't allow anything for flow. I believe if that check valve were swapped out to something that flows better then there would be much less problems.

I vote for removal, I vented the cam cover with a breather and my problems went away. The junky setup just doesn't work right, arggggg.

View attachment 46951

And go duel out the back (stock location on passengers side, and same location on the drivers)

Oh man, I was really hoping for a single 3", I am not a fan of duals on a truck.

 

[Xan]

Duals look awsome on these trucks, Are you crazy?

 

[Xan]

Remove the sts pvc system? Oh man, I really didn't want to hear this. I paid good money for this crap.

That muffler is going right after the turbo so it'll be the same as having a 5" downpipe - atleast that's the theory behind it. We'll see how she sounds and performs before we start making judgments.

The borla muffler is gonna sound a little bit ricey on the 6 cylinder just to warn you. But over all i think they sound pretty good

 

[Turdle]

Looking good so far. I too was hoping for a single 3" tailpipe.

 

[CDW6212R]

The turbo should alter the typical V6 non V8 sound, hopefully the result will be great. It sounds like you will have it done soon. Are all of the BA MAF meters 4" in size? I'm leaning towards the 2800, hopefully bolted to an air cleaner in the stock location.

 

[CDW6212R]

Thanks, I asked because the size will affect what kind of mounting on an air cleaner I make, and the air filter size too. It looks like a 4" inlet filter will work best, the EA filters have several in the 9" long by 4" inlet sizes. Night,

 

[rocket 5979]

The BA2800 is the same physical size as the BA2400. You can use that for size reference. Most likely the new BA2600 and BA3000 are pretty close in physical size to the others too.

 

[CDW6212R]

I thought so Robert, I just began checking into sizes for making an air cleaner. I gather that almost any of them will work for many engines in the range of 350-600hp. I shall ask James what he suggests, he has learned more than me about which are capable of my goals.

Amsoil has several universal EA filters, a few are in the 9.0-9.5" long range. Two are round and two are oval in shape. I need to pull out my air cleaner and see how much space is there, including through the fender. Robert, have you learned what space should be available around an air filter, in a container? Regards,

 

[rocket 5979]

I thought so Robert, I just began checking into sizes for making an air cleaner. I gather that almost any of them will work for many engines in the range of 350-600hp. I shall ask James what he suggests, he has learned more than me about which are capable of my goals.

Anyone of the BA series meter's will be able to support the power you plan to run. Pick whichever BA meter up that you can find for a good price. You might be able to find a good deal on a used one somewhere, unless you plan to purchase a new one from James.

Amsoil has several universal EA filters, a few are in the 9.0-9.5" long range. Two are round and two are oval in shape. I need to pull out my air cleaner and see how much space is there, including through the fender. Robert, have you learned what space should be available around an air filter, in a container? Regards,

What exactly do you mean by "container"?

Don if I were you I would cut a hole right behind your headlight and drop the tube and filter down behind your bumper/foglight assembly. I forgot to take a close look at Jim's old Exploder to see if there was enough room to do this but I cannot see any reason why not. No reason to pull hot engine bay air when you can get much cooler air just a few inches south of there. This was what I did with the Kenne Bell Explorer. The IAT's were a little cooler down there.

 

[CDW6212R]

There isn't really space there for anything but the typical trans filter. The inlet air comes from the grille opening, it is deflected to the space behind the headlights. I believe that the air there is cooler than what is inside the bay, another words a good air source.

When I say container I mean air cleaner, a box made to enclose the air filter. I plan to open up the hole behind the headlight slightly, it's likely about 5x6" now. The fender volume has an opening just under the headlight, just under the steel inner fender, and over the plastic inner fender. Thus a hole in the inner fender like Mustangs can allow a longer air filter and feed that portion of the filter. I'd like to make the air cleaner as large as possible of course, and seal it to the inner fender and radiator support.

I have the Volant air cleaner in my 99, and it is about as large of a container as can fit there. I'm not thrilled with how it fits in the stock space, it isn't held down at all, just pressure from the inlet hose keeps it from flopping around. It vibrates against the radiator support, wearing on the top. I think making a similar box will be easy, making a top that looks decent would be the interesting part. But still the air filter inside needs a certain amount of space out to the housing. Regards,

 

[frickea86]

This is NO easy task if you want perfection.

If it was easy everyone would do it. You'll really enjoy it when she is complete, it will look very clean and nicely tuck up out of harms way. Keep up the good work an where are the pics of the mock up??????