My 250+HP CRD build

thermorex · **Posted:** Wed Jul 09, 2014 7:20 am

papaindigo wrote:

If you can follow the arrows in this image it shows the direction(s) of oil flow

Having problems posting large enough image to view using ImageShack. They have redone things and I am at least temporarily lost in their redo. Let me see if I can shoot a copy to someone who can upload.

Image Shack sucks, they started to charge money lately, you may use photobucket, it's still free and images work fine, just tried it.

diesel_guy86 · **Posted:** Sat Jul 12, 2014 6:54 pm

Well got the exhaust done and took it for an 8 hour road trip to see how she felt.
Initial thoughts:

The power is up high, ~2500 rpms. When you want to accelerate it feels like you gotta give it more pedal than normal.

Since the power is up higher, its perfect for on ramp accelerating and passing. 40-80mph happens quick.

Very fun to drive now and the turbo whistle going through town is loud. Have had several people tell me it sounds like a truck, and asked if it was a Cummins.

Gonna drive it like this until I get the 2560 built. Then I'll throw that on for comparison.

Here's some pics of the exhaust, went 3" all the way to a 5" tip.

Here's a shot at 70mph cruise, anyone have gauges that can compare?

geordi · **Posted:** Sat Jul 12, 2014 9:31 pm

70mph cruise on my CRD (engine #2 had the gauges) I remember the EGT being about 800-900 and boost somewhere in the 8psi range. Seems you might be a bit light on the boost and heavy on the fueling at the same point?

I also had 215/85/16 tires, so taller and narrower than stock, and load range D at 65psi, so stiff and low resistance. Other than that, stock turbo, stock mechanicals, just Eco tune (an early one so I don't know if it was full torque or not) and the GDE trans tune.

diesel_guy86 · **Posted:** Sat Jul 12, 2014 10:01 pm

There's quite a bit of quality lost in all the transferring, but the egt needle is just above 900°, like 920. Boost was right at 5. The ecu was reading 7 psi. Cruising like this was when I could tell I had a bigger turbo. Normally slight pressure on the throttle and the boost would pick up and you'd lug ahead. On mine slight pressure does raise boost some but you can hear it isn't enough to pick up and go like it should. Its more like a gas engine where you have to press on the throttle until it kicks down and away you go. I think stepping down to the 2560 will improve everything, might choke on the very upper end.
On the 400 mile trip I only averaged 26mpg

I think this will go up when I change turbos. The lack of excess boost means more fuel is going out the pipe as heat instead of power. Ahhhh r&d........ :roll:

thermorex · **Posted:** Sat Jul 12, 2014 11:31 pm

My boost is about 8-10 psi, I'd say it hovers around 10 mostly and egt 7-800 @ 70. Since you dropped the vnt, you may have a bigger turbo lag... But I think Geordi got it right, may be a bit more fuel, but if the boost is so low, you may need the extra fuel to compensate. 26 mpg isn't bad, I think you were stepping on it quite often to hear the noise, lol. Also, what's the max boost observed on normal (not pedal to the metal) acceleration?

Make a recording with the turbo whine, I'd surely enjoy listening...

diesel_guy86 · **Posted:** Sat Jul 12, 2014 11:45 pm

Probably 15 psi. Once you get past 2500rpms and you keep pushing the pedal, the turbo really lights up and hits 28psi, accompanied by a nice compressor whistle

. trying to upload a video to YouTube now of a startup. I'll try to get a video messing around in it.

Here's startup, only revved to 1500 rpms.Liberty CRD 3" straight pipe, ball bearing turbo: http://youtu.be/9FmT0nS7HCM

Short drive off: CRD straightpiped short drive off.: http://youtu.be/jH66n06LsmM

thermorex · **Posted:** Sun Jul 13, 2014 12:26 am

Nice noise, I like it. Sounds like a bad arse hillbilly truck, lol.

diesel_guy86 · **Posted:** Sun Jul 13, 2014 12:43 am

Lemme know when those beers are cold. I'll bring it over and let ya have a go in it.

GreenDieselEngineering · **Joined:** Sun Jun 07, 2009 5:10 pm **Posts:** 1111

Don't worry about the high rpm flow, getting the response at the low end helps the feel and drivability more. The port geometry on the cylinder head is very flow limiting above 3500 rpm on this engine anyway.

I want to know how long that intercooler will hold up at 28 psi, they tend to have creep issues with the end tanks even at stock 20 psi over time.

diesel_guy86 · **Posted:** Sun Jul 13, 2014 8:27 am

I agree, I love diesel for the low end grunt and I lost that with this turbo setup. Gonna have to live with it like this for a couple weeks until the 2560 gets done.

racertracer · **Posted:** Sun Jul 13, 2014 9:18 am

This experiment is so freekin cool.

thermorex · **Posted:** Sun Jul 13, 2014 10:11 pm

diesel_guy86 wrote:

Lemme know when those beers are cold. I'll bring it over and let ya have a go in it.

Anytime chief, just let me know when you wanna take it to a spin towards Cleveland

. My dad will visit me from Europe in August, so I'll be a bit busy with him over the weekends in August, but otherwise, you're welcomed to come whenever you feel like taking a ride here! So it's official!

diesel_guy86 · **Posted:** Sat Aug 02, 2014 10:03 pm

Well I've put roughly 1,500 miles on it and have had 0 flaws or hiccups. I'm getting happier with the turbo, I think its loosened up alot. I'm now pegging the 30psi boost gauge and egts stay down pretty well. Well enough I loaded the original tune back in, and got this at a 75mph cruise today. And yes its accurate I checked, within a few tenths of a mpg:

Going northbound and more against the crosswind I was at 36.7 mpg.

Plans are already in the works to push the HP higher... But right now I'm REALLY enjoying it. And I promise I'll get a video soon of me messing around with it.

flash7210 · **Posted:** Sun Aug 03, 2014 12:23 pm

Can you do a quick recap of things youve done with the turbo?

What turbo are you using? Or what turbo do you want to be using?
What mods were needed to install the turbo?
What tune are you using?
Your last post indicated you went back to original tune. Did you mean "stock" tune?

diesel_guy86 · **Posted:** Sun Aug 03, 2014 2:19 pm

Yea no prob, I'm using a clone of a Garrett gt2860r made by KPA turbos. The quality and craftsmanship of kpa's turbos are double that of Garrett, smooth and clean cast housings, aerospace grade ceramic bearings that are faaaar superior to Garretts steel bearings. Also using a billet machined 63 mm compressor. The wastegate is tied shut. I want to use a 2560 for better low end boost, but I'm afraid I'm going to lose some top end power, so maybe twin turbos???

I think the exhaust manifold could be machined to accept the t25 bolt pattern, but I used some custom made adapters. One piece bolts onto the factory bolt pattern, and the other piece bolts onto that and that one has the t25 bolt pattern.

I removed the vacuum actuator system for the turbo and plugged off the vacuum supply to it. If you machined the exhaust housing to accept the turbo you could use the factory turbo oil feed and drain. I used an line and fittings for easy install and removal, I knew I was going to be experimenting with turbos.

The tune is a GDE hot tune that was modified to run without vnt control. Also has 10% defuel at idle, the 50hp injectors dump enough fuel at idle to cause it to idle rougher than normal. The defuel smoothed it out and there is no vibration at all inside. But the injectors are how I'm getting 270hp out of the original 200hp tune.

Did a 60 mile round trip today, 60 mph with no wind, no ac and got this:

racertracer · **Posted:** Sun Aug 03, 2014 2:29 pm

diesel_guy86 · **Posted:** Sun Aug 03, 2014 7:54 pm

It was actually pretty easy to get 40mpg, I didn't let it rev over 2k rpms, no more than 5 psi of boost, an kept egts at 800 or below. Put just shy of a hundred miles on it today and still above the full mark on the fuel gauge. Would love to see what it would do with more fuel efficient tires.

A list of what I've done:

Plugged and removed egr system
Weeks101 intake elbow kit
Samco hoses
In tank lift pump
ARP head studs
Valve job
Hot tanked head and intake cover. 100% clean now
3" straight exhaust with flow master hushpower series muffler
Removed fan and shroud
Cleaned intercooler out with kerosene till clean kerosene came out
Gen2 fuel head
3" cone filter and plumbing
Injectors cleaned, extrude honed 50hp, assembled, tested and calibrated
New water pump (graf) tstat, belt, idlers etc etc

My upcoming stage II build is gonna be performance ground cams, delete balance assembly, and twin turbos to give me good low end torque along with enough pressure to keep egts down at high rpms, and water meth injection. Would really like to do the water/meth first and see what that does to the egts and mpgs.

mass-hole · **Posted:** Sun Aug 03, 2014 8:36 pm

diesel_guy86 wrote:

It was actually pretty easy to get 40mpg, I didn't let it rev over 2k rpms, no more than 5 psi of boost, an kept egts at 800 or below. Put just shy of a hundred miles on it today and still above the full mark on the fuel gauge. Would love to see what it would do with more fuel efficient tires.

A list of what I've done:

Plugged and removed egr system
Weeks101 intake elbow kit
Samco hoses
In tank lift pump
ARP head studs
Valve job
Hot tanked head and intake cover. 100% clean now
3" straight exhaust with flow master hushpower series muffler
Removed fan and shroud
Cleaned intercooler out with kerosene till clean kerosene came out
Gen2 fuel head
3" cone filter and plumbing
Injectors cleaned, extrude honed 50hp, assembled, tested and calibrated
New water pump (graf) tstat, belt, idlers etc etc

My upcoming stage II build is gonna be performance ground cams, delete balance assembly, and twin turbos to give me good low end torque along with enough pressure to keep egts down at high rpms, and water meth injection. Would really like to do the water/meth first and see what that does to the egts and mpgs.

It looks like weeks101 may be working on a new intercooler. Hopefully that comes through since it sounds like you may be seeing some high IAT's

diesel_guy86 · **Posted:** Sun Aug 03, 2014 9:12 pm

Yes and I think it will be a great, permanent solution. I've been playing with the idea of an air-water intercooler to really bring the temps down. A good setup can lower temps below ambient temp. Gale banks sidewinder truck used 2 marine grade air-water units and was dropping the 400° charge air down to like 70° or 80°. Im not going that crazy, just showing the potential. Don't know if I want to use a separate radiator for the intercooler coolant, or convert the tranny cooler to be a radiator, and use a small cooler and fan for the tranny that's mounted elsewhere.

For right now I just want to enjoy the newfound power and mpgs, I need to take care of other things first like building the transmission and play around with water/ meth to see if I can crack 45mpg. I'll probably build as I go, its easier to tune this way and the jeep isn't down for as long. Wanting to do the cams at the 10k mile mark, that way I get to check on the studs and do a re-torque on em.

79wolf · **Posted:** Mon Aug 04, 2014 8:45 am

So what's your plan for the transmission :?:

My 250+HP CRD build

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