If its a fresh engine lighter weight is needed cuz.I use straight PM 50 which sounds thick but is actually rated at 20-50.PM doesnt break down like others and has a loooong service life.
could it be possible the water direction through the tap is wrong? never tried reversing it but it has an arrow on it..
Dads old car he used to have a ball valve(plumbing tap) used to turn it off in summer, and on in winter.. regulate the temp by fan speed and the window lol.. i find i use the window and heater a bit too..
Hey guys i made this report for my year 12 research project, my final mark was pretty high, 9/10 which was an A. It was also stated during the assignment that the intentions off the report would be to provide to the online forum , so here it is! , as you can see at the end all of this work is correctly referenced and the authors are recognised. Enjoy, feel free to add, sticky, use how the old thread was on the previous forum.
Introduction
Turbo charging a Crossflow in an XF falcon to produce around 300 rear wheel kilowatts (rwkw) requires a number of upgrades to the car. It’s believed that 220rwkw can be achieved reliably if the cooling, fuel and ignition system have been upgraded.[1] In order to achieve 300rwkw, research suggests upgrades need to be made to the engine, exhaust, diff and transmission, therefore most of these upgrades will be analysed throughout this outcome.
However it is important to note that before any upgrades and modifications are performed on a motor vehicle, it is necessary for them to comply with certain states regulations and design rules which can be sourced from your local authorities. [2]
Engine Upgrades
Bottom End
Research shows that the stock Crossflow engine requires engine upgrades to achieve any power near 300rwkw, including a full rebuild and replacements of major components to suit turbo application.1 [3] [4]These upgrades can be performed by a reputable engine builder[5] or can be performed independently with the use of car manuals on how to completely pull down and rebuild the engine independently.[6]
To build the engine, a bare Crossflow block will be needed. Crack testing and sonic testing should be done on the block[7], prior to having the block ‘zero decked’ to eliminate detonation during tuning.[8] Following this process will ensure that a safe and reliable engine is built.
CROSSFLOW BLOCK (Refer. User: BGDAV [ONLINE FORUM-xFalcon.com/Newbie Info to Turboing a Crossflow] (2009)
A vital key finding in research explained that many Crossflow engines had a number of bottom end upgrades for a turbo application of around 300rwkw. These upgrades included pistons and conrods.[9] 4Pistons that would be suited to a turbocharged Crossflow will have a high ‘cc’ dish, around 25+; which will help lower the overall engine compression.1Thorough research confirmed that many people who own a turbo Crossflow use two types of pistons in their engines. These pistons are either a 28cc dish piston manufactured by ACL or a 27cc dish piston by Hypatech.1, The pistons will need to have properly gapped compression piston rings suited to the engine and pistons that are going to be used.4It’s evident that using upgraded chromoly rings will also be of benefit and will last longer than standard rings.1
Another finding indicated that upgrading to stronger conrods will be beneficial to ensure the engine is very reliable as high rpm levels in the engine can damage the conrods when the engine tries to stretch them when the motor hits top dead centre.5Stronger E-Series falcon rods from a 4.0 litre engine can be modified through ‘shot peening’ to strengthen the conrod4 10 “The purpose of this process is to improve the resistance of the component against cracks and fatigue, which normally originate at the surface due to applied tensile stress”[10] and resizing to suit a larger diameter and stronger ARP rod bolts.
Furthermore, a significant budget is needed to contact a reputable conrod builder and have a custom set of forged pistons to suit the pistons and crank as this will be a lot stronger over the E-Series rods.[11],[12] Together the whole bottom end, including the harmonic balancer and flex plate to suit a choice of transmission will need to be balanced together by an engine builder.[13]
Another vital key finding is that components will need to be installed precisely and correctly to prevent any damage to either the block or components. In addition the bottom end will need all new gaskets, seals and bearings to ensure you have the equivalent of a fresh built engine. [14]
Top End
A number of components will need to be upgraded on the factory head to reliably to achieve 300rwkw. However, the engine will benefit from using a C-Series Crossflow head due to the larger combustion chambers, which will further lower the compression of the engine. 1
CYLINDER HEAD (Refer. http://www.atomicperformanceproducts.com/images/products/heads/IMG_8400.jpg)
To get the most out of head upgrades, stainless steel valves can be installed. It is also beneficial to have valves in the head recut to a larger size.3 Members on xFalcon have found from experience that the head has benefited from back cut inlet valves to suit a size 1.84 and face cut inlet valves to suit a 1.6 size.9
Research suggests that the head will also need to have upgraded valve springs to prevent valve float at high rpm, at least 120lb rated springs with compatible collects, retainers and valve locks.3 Research indicates you should also consider upgraded roller rockers, and push rods.9 1
Camshaft and Timing Chain
Upgrades over the factory camshaft will be needed to suit the engine and turbo rpm range. However the camshaft will not require a ‘high-lift’1 Many members and people with experience have used the off the shelf Wade242a cam, PSI_LTD (2012) suggests to get a custom grind camshaft from ‘Wade’ and anti-pump up lifters to match.3 Based on my findings I would recommend a double row timing chain to prevent slack in the timing chain and the timing retarding or advancing.
According to PSI_LTD (2012), and experience by Wes (2009) using ARP Head studs should be used instead of the factory head bolts, they suggest for a perfect fit, use 308 Holden motor studs.
Fuel
Analysis of automotive websites suggest that with turbocharged Crossflow there are two different types of fuel setups used, LPG (Liquid Petroleum Gas) and Petrol (Unleaded)1 4. Research showed that people with experience of building a turbo charged Crossflow suggested taking the LPG pathway for fuel supply. Reasons for to doing this include that the engine will able to run over a wider fuel mixture range without detonation when compared with petrol which makes it easier to setup and tune.1
Using an LPG system incorporates a number of different mechanical objects, the tank, lines, converter, and throttle body. As research shows that standard 3/8” flex lines are proven to over 260rwkw, a larger line would be needed to produce 300rwkw. [15]
Vital key finding shows that the Impco or Gas research B2 LPG converters are the most cost effective and best option for turbo charging. The converter will need to be boost referenced to compensate for when the turbo range psi increases. [16]
After the converter you will need a throttle body (gas mixer), you can use a 2 barrel manifold type Impco 225, Impco 4 barrel 425 or a Gas Research throttle body. Throttle body like the Impco 425 or Gas Research will need to be used, to flow more air and fuel, to produce 300rkwkw.[17]
Gas lock offs are also required for the systems, the best for turbo charged Crossflow’s are the Impco VFF30 lock offs due to their effective flowing. The lock off for the gas system will also require boost referencing similar to the converter.[18]
To hold LPG you will need a LPG tank, research has shown that a stock and new model gas tanks will only provide up to 220rwkw. A 4 valve tank would be the best to use, which have two outlets however you can have a new tank made with 4 valves. Tanks for turbo charged setups require extra valves as they provide more fuel which can supply up to 440rwkw.1
The engine can be self-tuned, and to help adjust the mixtures to effective levels a wideband air flow meter or air flow ratio gauge can be used.[19]
Unlike LPG setups, unleaded require upgrades to the stock fuel injection system. The stock injection system will require upgraded fuel lines, injectors, fuel pump, fuel regulator and a new fuel rail or modifications done to the existing one.4
Conclusion
In conclusion a number of factors outlined in the report will need to be taken into consideration regarding upgrades to the engine, differential, exhaust and the legalities of the modification. Specifically research showed vital upgrades in the car would be needed including performance engine components and installation of a gas system to enable an easier setup to tune.
Thorough research showed it was evident that when rebuilding the engine a lower compression ratio was most important to suit a turbo charger and custom exhaust with high flow mufflers. A number of sources also suggested a specific LPG gas system for a turbo setup which consisted of, boost referenced components and a 4 valve tank.
Through these upgrades it is evident that a 300rwkw Crossflow engine can be reliably achieved with most of the upgrades performed independently and balancing the engine, custom exhaust, custom conrods and pistons, custom cam performed by specialists.
A number of vital key findings were in subtopics of differential, transmission, Ignition and ECU (Engine control Unit), legalities and exhaust were located, however due to word limit constraints these factors could not be discussed.
WORD COUNT: 1502
Reference List:
Primary Source
Email:
Turbo Crossflow engine upgrades
Books:
Max Ellery’s-Falcon/Fairlane XD XE XF Vehicle Repair Manual published by M.R. Ellery Publishing Co. R.S.D. Axedale, Victoria (1995)
Secondary Source
http://www.infrastructure.gov.au/roads/motor/design/index.aspx
http://kreraceengines.com.au/services
http://www.pitstop.net.au/view/85/gregorys-manuals-information
http://www.ehow.com/how_6453472_check-cracks-engine-block.html
http://www.sohchonda.com/forums/topic/3775-hit-the-deck-explaination-of-deck-height-and-benefits/
http://www.wabrasives.com/index.php?pg=rubrique&rub_id=82〈=eng
http://fcp-engineering.com/29-custom-size-h-beam-connecting-rods
http://www.jepistons.com/PDFs/OrderInfo/custompistons-orderform.pdfs
http://www.custombalancing.com/enginebalancing.html
http://www.gasresearch.com.au/epg.html
http://ecomodder.com/forum/showthread.php/help-needed-propane-experts-custom-v8-propane-turbo-11194.html
http://www.factorypro.com/dyno/4gasEGAvso2sensor.html
Blogs Entries
User: MarkZE [ONLINE FORUM-xFalcon.com/Newbie Info to Turboing a Crossflow] (2009)
[uSER] Morgz [ONLINE FORUM-http://calaisturbo.com.au/archive/index.php/t-94486.html] (2006)
[uSER] vltrb-0 [ONLINE FORUM-http://calaisturbo.com.au/archive/index.php/t-97351.html] (2009)
User: Wes [ONLINE FORUM-xFalcon.com/Project Sleeper – TURBO XE DAILY 10 Second Car (2009)
User: BGDAV [ONLINE FORUM-xFalcon.com/Newbie Info to Turboing a Crossflow] (2009)
[1] User: BGDAV [ONLINE FORUM-xFalcon.com/Newbie Info to Turboing a Crossflow] (2009)
[2] http://www.infrastructure.gov.au/roads/motor/design/index.aspx
[3] Turbo Crossflow engine upgrades
[4] User: MarkZE [ONLINE FORUM-xFalcon.com/Newbie Info to Turboing a Crossflow] (2009
[5] http://kreraceengines.com.au/services
[6] http://www.pitstop.net.au/view/85/gregorys-manuals-information
[7] http://www.ehow.com/how_6453472_check-cracks-engine-block.html
[8] http://www.sohchonda.com/forums/topic/3775-hit-the-deck-explaination-of-deck-height-and-benefits/
[9] User: Wes [ONLINE FORUM-xFalcon.com/Project Sleeper – TURBO XE DAILY 10 Second Car] (2009)
[10] http://www.wabrasives.com/index.php?pg=rubrique&rub_id=82〈=eng
[11] http://fcp-engineering.com/29-custom-size-h-beam-connecting-rods
[12] http://www.jepistons.com/PDFs/OrderInfo/custompistons-orderform.pdfs
[13] http://www.custombalancing.com/enginebalancing.html
[14] Max Ellery’s-Falcon/Fairlane XD XE XF Vehicle Repair Manual published by M.R. Ellery Publishing Co. R.S.D. Axedale, Victoria (1995)
[15] http://www.gasresearch.com.au/epg.html
[16] http://ecomodder.com/forum/showthread.php/help-needed-propane-experts-custom-v8-propane-turbo-11194.html
[17] [uSER] Morgz [ONLINE FORUM-http://calaisturbo.com.au/archive/index.php/t-94486.html] (2006)
I've almost completed my XF OHC project. Just a few loose ends to tie up before I attempt a roadworthy certificate for her. One of the last issues was an intermittent problem with starting the beast. Sometimes she'd start with no dramas and at other times she would turn over on the starter but there'd be no ignition spark. Ignition components tested okay. Substituting in a an earlier non-Smartlock 0DAC ECU (EB1 Falcon) would see the vehicle start every time but with the 6DAA or 6DAB (EL Falcon) ECUs I have it would exhibit the sometimes start-sometimes-not scenario - so I figured the problem to be related to the Smartlock feature.
A google search resulted in approximately a baziliion search items related to where the module exists in XG Falcons. I've used an XG Falcon harness in my project. The factory XG workshop manual supplement I have doesn't actually have a Smartlock section in it. Thanks Ford for the remarkable efforts regarding documentation!
So...as a public service I thought I'd document my efforts at finding its location.
The module is not in the location one may find find it in ED/EF passenger vehicles that were produced at the same time as the XG. It has been relocated in the XH as well. Turns out it's a little red fucker that can be found behind the passenger side dash mounted speaker. It's snugly fitted in there and not easily accessible. It's not the same module as exists in ED/EF/XHs as well. Its rivetted to a bracket which is located by screws to the dash assy.
Sometimes the screws (two of them) are accessible from the glovebox and sometimes they are forward facing and not accessible at all with the dash in situ. Depends on the vehicle...and when it was manufactured.
Secreted away...Ford obviously figured they'd developed a top-notch immobilizing system that never needed attention. WRONG.
You don't have to fully remove the dash assembly to get at it but all dash retaining screws/bolts, the handbrake location hardware and centre console screws need to be removed in order to located the dash far enough back to get your hands/tools in behind the dash
Here's the dash pulled forward enough to see it : it's that red box.
Here it is free of its dash mounting:
Here's my mod that allows access to the little bugger should it give issues in the future:
It has enough harness to be relocated in the glove box to give easy access. A relief has been cut into the rear of the glove box door to allow operation of the door.
Next stop...a bypass module if it gives me further grief!
Crossy pushrods are their inbuilt mechanical rev-limiter. Been peaking it?
Dropping revs fast will also kill them, like selecting first instead third at 100 k's
I hope I dont appear to be condescending, but in Sedans, only XD came out with Leafs springs, so it isn't an XE.
As Steve says, it might just be XD with XE front.
Check you ID tags in the enginebay, it should say.
.
I cant help but think the worst when I see this, You dont know the history, You dont know that only XDs have leaf springs. I really hope someone hasn't done you over and sold you something plated wrong, unplated or reshelled a stat writeoff.
.
Check the plates and let us know
Making this as sort of a news spot for Megasquirt ECU related things.
Try to keep the off topic questions out of here, If you need help with your megasquirt or choosing a setup make a new thread and i'll come over there and help, if you don't get a reply withing a day PM me with the link to make sure i find it.
I'll start with:
I'm interested in very soon purchasing a RS232 to bluetooth adapter.
For those in the loop it's been about for a while, but the big thing on this front at the moment is there is finally some reliable dashboard software to interface the Megasquirt with an android powered Tablet (slate PC) or mobile phone (such as galaxy S3)
Wireless, 100m range and awesome.
The hardware required can be purchased pre-configured so it's basically plug and play. and im interested in purchasing some of these units asap.
After expressions of interest. Organize a bulk buy right here for people interested.
it will work out between $60 and $70 bucks inc postage for the RS232-bluetooth adapter. the software is +$10 from the android play store (but there is a free trial)
I'll be between Brisbane, Canberra and Sydney over the next few weeks so logistics for those areas is sorted.
More info:
http://tunerstudio.com/index.php/shadowloggerms
http://tunerstudio.com/index.php/shadowdashmsmenu
Taken last year after I fixed the car after leaving it sit for so long!
The car is EFI.
Camera does love being blown around by exhaust and having shit blown all over it!
This XF Ghia is fitted with a 2.5 inch exhaust, a hot dog and single box. It has no cat because it's a march 1985 build and doesn't need one. It has over sized exhaust valves (among other things) and standard cam (I hear you laughing )
Its power is down low, the motor wasn't built for straight line power.
The sound is crisp and clear and I missed it for 2.5 years.
'Nova reacted to jamie247 in 393 cleveland
'Nova got a reaction from Schmoburger in my car spat another pushrod today
'Nova got a reaction from mcfly94 in Preparing a 250 crossflow for 300RWKW turbo application.
'Nova got a reaction from LTD083 in Handbrake Issue
'Nova got a reaction from Mr Polson in Handbrake Issue
'Nova got a reaction from SPArKy_Dave in my car spat another pushrod today