TD04 turbocharger

[kayweb]

I had the good fortune to come into the possession of a Mitsu TD04 complete with wastegate/BOV and a 9.25" x 7.25" x 2" intercooler from a Saab for 40 dollars.
Main question:
- How quickly will it destroy a B3?
Followup questions:
- Is it possible to modify the factory exhaust manifold (just for now) to mount it?
- How prone to detonation is the B3? (will I need to run water/meth injection if I have an intercooler)
- Should I stop now and just turbo my Honda instead?

[Aaronbrook37]

0. Intro and Notes

Good fortune indeed! Can you provide a bit more information on the turbo... saying you have a TD04 is like me saying I have an IHI turbo. You have no idea whether we're talking about a 10lb house cat or a 500lb lion if you catch my drift. Get some pictures, info, or part numbers off of the label and or compressor housing for us. Once you do, I will find a compressor map for the turbo and map it out for you to see if it will be a good match for an efficient turbocharger for a 1.3L engine that flows the way the B3 does. I will also calculate power output estimates for you based on your heat management techniques (including intercoolers and water/meth injection) and your desired levels of boost. Now onto your questions:

1. Will a turbo necessarily destroy a B3?

a. Some problems can be made worse by installing a turbo: poor heat management, weak cooling/ignition systems, and poor oil pressure/volume for example.
b. Mazda motors are pretty durable things... and you're not likely to bend a rod or a blow a head gasket just for installing a turbo and running everyday boost.
c. I'd say your clutch, transmission, and tires will give way long before the engine does assuming it's in decent shape.
d. Run a compression test, do a leak-down, and ensure all of your maintenance items are up to date.
e. If your engine is in rough shape, I'd encourage you to upgrade to a B6 or B8 or BP before you go turbo.

2. Is it possibly to modify the factory exhaust manifold to mount it?

Yes, absolutely. On either a Festiva or an Aspire manifold, you can chop and weld to create a hack-job manifold that will work in the meantime. It won't flow great though... something to consider if the TD04 of yours is the size I think it to be. The larger your turbo, the more important it is that you have a manifold that will flow well enough to support it and not be a restriction or bottleneck in the system.

3. How prone to detonation? It depends on your setup, really. A few thoughts:

a. High flow zero back-pressure exhaust. Mandrel bends, 2.25-2.5", high flow muffler/cat/resonator.
b. High octane gasoline. With the Festiva's engine compression ratio, I'd recommend 91+ if you can afford it. 93/94 won't be necessary.
c. Manage your engine's heat well with a large radiator (Festiva auto or Civic aluminum) and fresh coolant.
d. Run cooler heat range copper core spark plugs only. NGK V-Powers are cheap, abundant, and efficient.
e. Start small with boost, and be very conservative for the sake of your engine, transmission, and tires.
f. Insulate your manifold, turbo, o2 housing, and downpipe to retain exhaust gas velocity and reduce engine bay heat.
g. Figure out your plan for ensuring you don't run lean... better to be on the rich side a little as you know.
h. That intercooler is too small for anything other than stock boost if you ask me. It won't flow all that well unfortunately.
i. Water/meth is great, but unnecessary in my opinion if you invest that $200-500 in other areas.

4. No, in fact I'd encourage you not to turbo the Honda. This is all opinion obviously.

There's nothing novel or inspiring about Honda turbos if you ask me. I give a great degree of credit to those who opt to turbo B3 motors, as I think they can be a lot of fun and have a lot of potential in the right hands. Though the head flow might well be superior on your Honda (particularly if ported/Vtec/DOHC), the compression may well be higher or the engine bay may be more cramped. Further, the rarity of turbo Festivas and in particular small-engined ones makes them a lot more fun to own, drive, and share with others.

[Festevil3]

Aaronbrook37 what a well written response

Here is my summary turbo your B3

[gauge_half_inch]

I can tell you from experience on the 2ng b6, 12psi is way too much for the stock graphite head gasket. I used a dsm t25/td04 turbo and it was a little small. The wastegate was the highest stock one and peaked at 15lbs on my gauge. It reached that at 2900rpm.

[kayweb]

IMAG0694.jpg
i can take a better picture if that's not sharp enough. My SLR is on the fritz, new shutter is acting up again.
BOV is marked k5t09 274
wastegate is marked as follows:
T11771
1710
(i always get the two confused, when i say wastegate i refer to the valve attached to the compressor, and bov the valve attached to the intake.)

[kayweb]

also, this is the honda:

2.2L, single cam, 2600lbs scale weight on the title vs 1700 for the festy's title. (that was before the weight loss but still, heavy)

[Aaronbrook37]

[ATTACH=CONFIG]12458[/ATTACH]
i can take a better picture if that's not sharp enough. My SLR is on the fritz, new shutter is acting up again.
BOV is marked k5t09 274
wastegate is marked as follows:
T11771
1710
(i always get the two confused, when i say wastegate i refer to the valve attached to the compressor, and bov the valve attached to the intake.)

That would be a turbo off of a Mitsubishi 3000GT... known as a 9B. They're the smallest of the TD04 turbos and don't have a whole lot of potential for power output. On a B3, it would be a pretty fast spool but I can't say for certain how it would really perform. It may well run out of steam before redline if you try to boost it anything more than whatever the wastegate is set at. You certainly did get a good deal for that turbo... but don't expect to make gobs of power with it.

[kayweb]

I really don't want too much, if I broke 3 digit figures I would be happily surprised. I rarely push it anywhere close to redline, the quick spool is just what I'm looking for.

[jesteratc]

pfft. 3 digit figures can be reached with a stock festiva and a long enough road.

[Powerstiva]

And by long enough you also mean straight enough...

[Aaronbrook37]

I really don't want too much, if I broke 3 digit figures I would be happily surprised. I rarely push it anywhere close to redline, the quick spool is just what I'm looking for.

Unfortunately I don't have time to write out much of a response today, but I will provide a few links that you can use as a starting basis for your research and development process. The more reading and planning you do, the better your result will be both in terms of economics and in terms of performance as well. It's good to lay out on the table how much you intend to spend, because it will greatly impact the sorts of answers you will get. I'll assume you want to spend as little as possible, in which you should print off these threads for some light reading.

http://www.fordfestiva.com/forums/showthread.php?38622-B3-Turbo-on-a-budget

http://www.fordfestiva.com/forums/showthread.php?39958-My-B3-T-setup

[kayweb]

Here's my plan thus far:
- hack up factory downpipe to mount turbo
- intercooler front-mounted next to radiator since radiator is so small
- tap sump for oil return or use sandwich adapter
^ i have four inlets on the turbo, should I run coolant from the IACV or some other source or is it oil-cooled?
- junkyard oil cooler repurposed from an air/water intercooler?

any recommendations on managing timing / fuel delivery with this engine?