Remote Turbo Setup Questions
 

I just purchased the first part of the turbo setup, a Holset H1C instead of the HX35 due to the larger exhaust turbine. The plan is to mount that under the passanger side of my yukon where the muffler is use two rectangular intercoolers about 26x10x3 with e-fans and run the intake piping into a factory or closed style intake so it looks fairly close to stock under the hood. Run 1/4" steel pipe for the oil supply to the turbo and a 3/8" return with a moncal pump. Swap out to 43# injectors and have it tuned by my neighbor that owns a speed shop with a dyno.

Some questions that I have are does any one know if a factory or s&b intake pipe to the tb will hold up to low boost pressures about 7lbs?

With the wastegate and bov where is the best locations for them or does it matter, I have not selected which ones will be used, but for right now flanges will be welded to the piping and capped off so they can be installed later.

For egt and wide band o2 sensors on a remote turbo are they mounted before or after the turbo?

On the intercoolers, running two of them gets a little pricy with name brand ones, has any one have any experience with the cheeper no-name chinese ones since I could get two of them for the price of one name brand one.

Are there any alternatives on where to feed the oil back to the engine besides tapping the pan and using the oil filler cap? I was thinking about welding a 90 degree piece of pipe into the filler extention so the cap is still easily acessible and make the return look like a heater or pvc hose.

What can be done about passing emissions with a turbo setup, the engine compartment will be pretty much stock looking and I have the carb sticker for the intake. Sometimes they look under the car with a mirror to check for a muffler, but a turbo does not exactly look like a muffler.

I apologize about all these newbie questions, but I have finally fall into the turbo crowd, use to think they were only for diesels and the import crowd. With your assistance hopefully everythign will be running by next month, thanks for the help.

I don't think the stock plastic intake tube will hold up to boost and the heat that the boost will create. I'm not sure what the plastics elasticity temp range is but it was never designed to endure boost and heat. When its being used on a NA engine the cooler or ambient air temps keep it in a stable state.
I remember when Parish tried using reinforced rubber tubing instead of silicone for some temporary connections, and they expanded and blew apart!

Your emmision testing station will use mirrors on sticks to look at the underside of your vehicle so be careful there.

Sounds like a cool project, I would give the intake pipe you already have a shot and see what happens. You could always rig a test for it with shop air, but be careful, compressed air and plastic don't get along.

You will want the wastegate somewhere convenient before the turbo, check to see which one you want to make sure the flange you weld on will fit.

You might need a small section of steel of aluminum pipe before your S&B pipe to weld the flange on.

I would leave the factory 02 locations alone, if you need to add a wideband I would do it near the stock manifolds if that's what you plan to run. EGT before the turbo.

Myself being a member of Union labor (plumbing/pipefitting), I would go with the USA intercoolers, but I'm sure the Chinese ones would work if they don't crack.

I don't know where the best spot to return the oil is, I'm sure you will get response on that.

Passing emisions would be tough if they look underneath for a visual, maybe you could get half a muffler can and hang it underneath the turbo for a fake-out, but who knows? I think the tune would be very important to pass the sniffer, definetly need cats too.

Good luck, it would be awesome to see some pictures when you are finished.

When I installed my rear mount turbo, I too was concerned about emissions testing and wanted everything looking stock under the hood. I fed the cold side pipe into the underneath of my air filter box, hoping the plastic would hold up.....
With the turbo running at min boost (4 - 5 psi), here's what looked like after the first hard run........

http://www.denalitrucks.com/coppermi...n%20airbox.jpg

You could remove a valve cover, drill and tap it for a fitting for the oil return. Or have a bung welded to it to give it something a little beefier to plumb into.
I've been contemplating doing this for my STS set-up.

:judge: Boost>Plastic :judge:

I have a LM-1 wideband O2 sensor and it was recommended that I put it after the turbo. For accurate readings you need it in a cooler spot with less exhaust turbulence. Front or rear mount the WBO2 should go after the turbo AFAIK.

The BOV in the STS system mounts in the pipe just before the MAF in the engine compartment. The wastegate mounts in the hot pipe just before the turbo and mine is vented to the atmosphere.

Good luck with project. :)

Also I mounted my EGT gauge about a 10" below the exhaust manifold. You want to know how hot the engine EGT's are, not the turbo..... Wideband after turbo alwas. From what I've been told. 02 sensor don't like the heat they could see being inbetween the engine and turbo... You could alwas look for some STS piping with a CARB # :devil:

could you leave the factory box and intake tubing, but run the metal tubing through it? using it to disguise it?

So I take it that the wide band goes after the turbo, egt after the manifolds. I guess plastic is no good when it meets pressure and heat. How well does some fiberglass reinforcement inside the intake tube hold up? Or should i just go with metal and keep the intake just for inspection purposes. Thanks for all the help.