I suppose some context is in order from the near 4 year hiatus.
So, the turbo DID get installed and it was a learning curve. Required a bunch of additional enhancements and modifications.
Including upgrades to the fuel system. We dropped the tank, pulled the pump and OEM regulator and installed a 255LPH pump into the OEM hanger/module and added a boost referencing fuel regulator by Aeromotive
Before:
After:
Required a bit of fiddling and setting the regulator to roughly 60psi (Spec called for 58psi +- 5 so we went on the high side)
The system works, there is an 'evap leak' code because we mounted the regulator to the vent canister filter. There is no issues in adding fuel, no smell of fuel around the rear of the car.
This added a new 'noise' to the car as you can hear the fuel pump working when the car is at idle and you stand at the rear of the car.
It works, and was working flawlessly for 2 years with zero fuel tank issues including adding fuel.
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The intake from turbo to engine went through a few variations, started with the pipe to K&N tube, then same idea with a bov added and that greatly fixed the blowing apart issue under decel (when we finally got the BOV set decently) and then FINALLY after blowing out a few of the elbow boots to the throttle body it was upgraded to a steel tube that was later wrapped in reflect a gold tape to keep things cooler going into the engine which brings about the next 'modification' which was a simple hole cut in the hood to help let the heat from the turbo out of the engine bay.
(only photo I have with the gold wrap, shows the evolution of the hole in the hood)
The hole in the hood was to help excess heat exit the bay. After a normal drive home the hot side of the turbo would be around 500+* (Can't remember C or F of the top of my head) so I cut a baisc hole.
Car enjoyed relatively regular driving, eventually got it swapped over to a 3.2L ecm/tcm and had to space out the MAP sensor from seeing boost pressure (achieved with extended harness and vacuum hose with check valves.
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Power wise, it was run on the dyno. But it was run on the dyno prior to making small adjustments to the way it was setup. Running a 3.5HO upper plenum meant it had a vacuum actuated center runner, so when I applied 'boost' to it, the runners opened, but under low throttle input the runners were closed having a 'long runner' for better low end torque.
Now, one thing to remember about the power it makes is that this is an unopened 3.5HO from a 2000 300M with well over 300,000kms on its stock internals
At the wheels it ran 142.3hp at 4600rpm and 171.3ft-lbs @ 4200rpm. Why so early in the power band? Injectors. With boost, the 21lb injectors can not fight with the additional 6psi I was attempting to stuff into the cylinders (math works out, atmospheric pressure is 14psi, + 6psi(boost) = 20psi vs 21psi injector cap) so there was a significant drop before 5000rpm as knock sensors started fighting to keep the engine alive.
There is definitely a lot more potential for the engine when I make the change over to the Holley Dominator setup when I have everything for that sorted 100% with the various required harnesses.
That gets the 'turbo' mostly sorted, next update later will be the paint and body work update.