TurboTalk -1.6L 1st Gen w/ Intake Air Temperature & Manifold Ambient Pressure Control

[northguest47]

So its on to the fuel controller, as the stock ecu won't be used likely. This is the part that 06T200 says can 'get old pretty fast'. So, I need full assurance from a company that they can take over the fuel delivery of this motor, and I don't know the ECU firmware version, etc... yet.

[northguest47]

Chevy, is often thought about as the Corvette, the 'car that the well off man buys'. Well, best chance i got is to make a cheap 'hot hatch' and pass it.

[06T200]

cool, thanks for the update. Is this car a 5 speed stick or auto?

[northguest47]

So in my initial work here I have received some very great responses on how to proceed here, given that its a 6258 with a t25 housing. Initial project obstacles are notably, 'the wiring harness' which is a technical piece of magic, and what EMS to use. This leads me to one responder asking what the trigger pattern is for the motor, because we need to know that first. So thats all for now. I bet the shop that responded to me would perhaps do the harness, but they were essentially saying its one of the technical, and expensive parts in the project.. so good to know there. I guess its a custom harness for this one..

[northguest47]

06T200 its a five speed running synthetic gear oil.. when I get back I'll post the gear ratios and modified ones with the smaller tires. (edit: april 2017 tba,185/55 series vs. 185/75 series test, 3rd, 4th, 5th gear roll-ons)
Now I just gotta talk about one thing with the motor I've noticed over the past ten years - its always at the same temperature, day, night, winter, summer, flogged, cruising, its always 190-196F, for all ten years. And to me that just seems really great, in other words its never even had problems keeping temp. So since the turbo setup will add more demand to the cooling system, perhaps keeping the stock radiator, but increasing the coolant volume by 50% might help.. something to look into anyways. And the inter-cooler, is it necessary for this setup, I wonder. Can it be omitted if the maximum compression is dialed down. (edit:april 2017 tba the answer is no)

[northguest47]

cool, thanks for the update. Is this car a 5 speed stick or auto?

its a 5 speed 06T200, you can learn more about its worthiness here

[northguest47]

so since this project is a year (edit: april 2017 tba a year or two or three) away I might edit the posts a bit to clarify the butter. and keep it to more point form..
budget-4 thousand canadian dallers (3090 usd)
-----------
-Borg Warner EFR6258 1st and only choice so far perhaps a second and third choice, scrapyard, twin scroll
-T25 Housing
-Inter-cooler can connect to existing AEM CAI true, see Nemasys' thread for inter-cooler placement (ie. not in the bay)
-Engine Fuel Delivery Computer install, trigger pattern, pressure/temperature open and closed loop control, sample interval, etc
-Intake and Exhaust Manifold, beefy flanges, over-design, increase wall thickness, flange thickness, and diy it (budget savings)
-Wiring Harness outsource several shops interested, they are all in the states, custom harness

if only someone else was interested... that would be 2 people interested in a wiring harness. i'm no fool though, "everybody talks turbo", and 'none of them actually do it'. then theres me.. look how long it took to lower vs. 'dreaming about lowering'
the forum poster Nemasys has the best writeup on the turbo concept, maybe he would be interesting in directly consulting on this project. i think folks intutively can make fun of the idea, of spending 'more money on a turbo than the car is worth'. You see, if this one fails, there's another just one auction away..

[06T200]

Hey Northguest, I was chatting with a buddy of mine, and he is doing a custom EFI on a new build. Not to sound like a salesman, this stuff was new to me so I thought I would share it. Holley and a few others have 'self learning' controller's (dominator/terminator) out now and they now talk CANBUS on a few pins, mainly to talk to the IC and TCM's. These are not plug and play setups, so lots of sensor sorting, (they do talk to ITK O2 sensors fine) but they are very tunable and will even self build the mapping curves on the fly. Block learning, built into a custom ECM! How cool is that!?

With a little hacking of the Aveo's CANBUS you can sort out what values the ECM shares with the IC and program those values into the new controller - if you want full instrumentation. The niche is to have a fully tunable fuel, ignition controller that has the same manors as a street/daily driver setup, so things like the tach, speedo, etc, will function. This might be something worth looking into as they bring more protocols online to work with many types of cars native CANBUS format. It seems there is a huge market for this type of controller, and can be configured as speed density, MAF or MAP/boost and has all the right stuff for a high boost streetable setup. I don't know if it will interface with the stock DIS coil, but MSD and Holley have DIS ignitions for 4 cylinder applications that plug right in. Kind of pricey, but it is a dream for a custom build turbo setup IMO as much of the tuning is done for you and should be very drivable in the end.
FYI

[northguest47]

Thanks, 06T200! Wow you manged to cram a lot into that post. Will start researching into all of this for sure - you present a more technical understanding of the whole tuning setup. I mean I took the theory for a lot of this but it was more just for general control theory, not specifically cars. I remember when the Powercommander5 came out and there were guys using its auto-tune feature on motorcycles. Nemasys mentioned Megasquirt, looks like you are saying there probably at least two more to look into .. well I appreciate being given new avenues of research to help me focus my time and effort more efficiently. Until next posting time.. adieu.

[06T200]

With any luck we will see more of this intelligent design when it comes to custom DIY engine management. If I had a dime for every failed project that boiled down to poor engine management problems, I would be rich! lol In seriousness I think this is the way of the future, rather than dealing with custom one off hand modeled/mapped configurations that are a nightmare to tune AND keep running when they act up. I have yet to see a piggyback system or a MS run for any length of time before a nasty lean out problem, or the never ending struggle to silence the MIL light on a piggyback setup. And these are not problems specific to the Aveo, they apply to just about any car that does not have a huge R&D market to pull from, given the fact that many 'plug-and-play' products are not that great either for the more popular lumps like Honda's. With any luck the aftermarket will bail us out of the mess.