Thread Starter
#1
Date of build - Feb/March 2011-
This thread is in many ways a continuation of my M800 carb turbo build.
While working on the carb Maruti 800 turbo setup, I decided to buy an MPFI M800 and turbo-charge it someday. Later, bought myself a stock MPFI 4 speed M800 and subsequently started collecting the necessary turbo bits. The goal with this setup is similar to the my Baleno turbo build - to be fun, reliable daily driver. The only thing different here is – I wouldn’t mind pushing/boosting it a bit more (M800 parts being not as expensive and are easy to come by).
Though I have my Turbo Baleno, I wanted something smaller, capable and cheap to run around in – M800, it was. That makes it " Two boosted suzuki siblings"
I picked up the following – BOV, couple of intercoolers, Swift diesel Turbo and few accessories. Then I came across a slightly larger MHI turbo and decided to do the build with it.
One of the initial problems (that worried me much) - very tight space for the turbo & ex-manifold. The oil filter jutting out in the front is a problem to have a the turbo hang below the manifold. Placing the turbo above the manifold may cause heating issues for the spark plug wires etc. since it exits very close to the turbo/exhaust manifold.
Now comes the shopping list and running errands – Listed out most of the hardware etc needed for the build and started shopping.
1. Turbo ex-manifold - flange plate & exhaust flanges– Gas cut & machined.
2. New stud/bolts for turbo exhaust manifold
3. Thick MS pipe (45 & 90 degree bends) 1.25 inch dia for fabricating ex-manifold.
4. Copper sheet – for cutting out turbo/ manifold gasket.
5. 4 Bolts were machined and used in the Banjo setup for oil and coolant supply line.
6. 2” MS pipe (full length) for fabricating the exhaust.
Started work on the car on a Tuesday morning.
1. Started by taking out the bumper, grill etc.
2. Dismantled the stock ex-manifold and exhaust pipe.
3. Temporarily mounted the turbo to the best position possible.
4. Ex-manifold MS pipes were routed according to the turbo position & tack welded
5. Removed the turbo ex-manifold and got it TIG welded.
6. Oil and coolant lines & accessories were modified/fabricated to suit the build
7. Got the 2” MS pipe cold bend – cut appropriately and used for exhaust system.
8. Fixed the TRUST intercooler at a suitable/chosen position.
9. Routed the intercooler plumbing from the turbo.
10. Routed the intercooler plumbing to the intake manifold.
The build was almost done by Friday. Saturday was the final fitting and rechecking for leaks etc. And sure enough there was a leak – oil leaking at the banjo bolt at the turbo oil supply source (probably because of a faulty machining of banjo bolt). It was fixed temporarily.
The car cranked up just fine. Had a short drive to check how it felt. The turbo kicked in quite late as compared to my Turbo Baleno but I guess it was not getting the right amount of fuel under boost. Soon after, it felt like the fuel supply being cut off (maybe because of the MAP sensor boost issue) – but there were not CEL, unlike Baleno when on boost.
After sometime below mods were done -
1. Installed Race Dynamics piggyback ECU.
2. Installed new MGP clutch & pressure plate (Old one packed up sooner than I thought)
3. Installed a new set of upgraded injectors (Baleno)
4. Rigged in a Autometer boost gauge and a pricol tachometer.
5. Also installed an EGT gauge to keep tab on exhaust temp.
The new up sized injectors were able to supply enough fuel.
This thread is in many ways a continuation of my M800 carb turbo build.
While working on the carb Maruti 800 turbo setup, I decided to buy an MPFI M800 and turbo-charge it someday. Later, bought myself a stock MPFI 4 speed M800 and subsequently started collecting the necessary turbo bits. The goal with this setup is similar to the my Baleno turbo build - to be fun, reliable daily driver. The only thing different here is – I wouldn’t mind pushing/boosting it a bit more (M800 parts being not as expensive and are easy to come by).
Though I have my Turbo Baleno, I wanted something smaller, capable and cheap to run around in – M800, it was. That makes it " Two boosted suzuki siblings"
I picked up the following – BOV, couple of intercoolers, Swift diesel Turbo and few accessories. Then I came across a slightly larger MHI turbo and decided to do the build with it.
One of the initial problems (that worried me much) - very tight space for the turbo & ex-manifold. The oil filter jutting out in the front is a problem to have a the turbo hang below the manifold. Placing the turbo above the manifold may cause heating issues for the spark plug wires etc. since it exits very close to the turbo/exhaust manifold.
Now comes the shopping list and running errands – Listed out most of the hardware etc needed for the build and started shopping.
1. Turbo ex-manifold - flange plate & exhaust flanges– Gas cut & machined.
2. New stud/bolts for turbo exhaust manifold
3. Thick MS pipe (45 & 90 degree bends) 1.25 inch dia for fabricating ex-manifold.
4. Copper sheet – for cutting out turbo/ manifold gasket.
5. 4 Bolts were machined and used in the Banjo setup for oil and coolant supply line.
6. 2” MS pipe (full length) for fabricating the exhaust.
Started work on the car on a Tuesday morning.
1. Started by taking out the bumper, grill etc.
2. Dismantled the stock ex-manifold and exhaust pipe.
3. Temporarily mounted the turbo to the best position possible.
4. Ex-manifold MS pipes were routed according to the turbo position & tack welded
5. Removed the turbo ex-manifold and got it TIG welded.
6. Oil and coolant lines & accessories were modified/fabricated to suit the build
7. Got the 2” MS pipe cold bend – cut appropriately and used for exhaust system.
8. Fixed the TRUST intercooler at a suitable/chosen position.
9. Routed the intercooler plumbing from the turbo.
10. Routed the intercooler plumbing to the intake manifold.
The build was almost done by Friday. Saturday was the final fitting and rechecking for leaks etc. And sure enough there was a leak – oil leaking at the banjo bolt at the turbo oil supply source (probably because of a faulty machining of banjo bolt). It was fixed temporarily.
The car cranked up just fine. Had a short drive to check how it felt. The turbo kicked in quite late as compared to my Turbo Baleno but I guess it was not getting the right amount of fuel under boost. Soon after, it felt like the fuel supply being cut off (maybe because of the MAP sensor boost issue) – but there were not CEL, unlike Baleno when on boost.
After sometime below mods were done -
1. Installed Race Dynamics piggyback ECU.
2. Installed new MGP clutch & pressure plate (Old one packed up sooner than I thought)
3. Installed a new set of upgraded injectors (Baleno)
4. Rigged in a Autometer boost gauge and a pricol tachometer.
5. Also installed an EGT gauge to keep tab on exhaust temp.
The new up sized injectors were able to supply enough fuel.
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