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Preparing a 250 crossflow for 300RWKW turbo application.

By mcfly94, in Forced Induction Tech

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mcfly94    169

mcfly94
Posted

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.

 

100_1665_zpse90e8fb6.jpg

 

 

 

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.

 

Crossflowblock_zps86ab2bf7.jpg

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

 

MahlePiston_zpse78a7fa3.jpg

PISTONS                                          

(Refer. http://www.jepistons.com/PDFs/OrderInfo/custompistons-orderform.pdfs)

 

EC_002_zpsfbe5fff8.jpg

CONROD                                                     

(Refer. http://www.atomicperformanceproducts.com/images/products/conrods/EC_002.jpg)

 

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

 

IMG_8400_zps64012aa1.jpg

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.

 

O9I0047_zps6d85d477.jpg

                    CAMSHAFTS

(Refer. http://www.atomicperformanceproducts.com/images/products/camshafts/O9I0047.jpg)

 

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:

  1. Turbo Crossflow engine upgrades

                Books:

  1. 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

  1. http://www.infrastructure.gov.au/roads/motor/design/index.aspx
  2. 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

  1. User: MarkZE [ONLINE FORUM-xFalcon.com/Newbie Info to Turboing a Crossflow] (2009)
  2. [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)

 

robbie, XTREME KARTS XF, Crazy2287 and 1 other reacted to this

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mcfly94    169

mcfly94
Posted

Where can I get one of those 24 valve twin cam heads for my crossflow?............ :P

haha when i did my project i couldnt find a neat photo of a crossflow head.

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PSI_LTD    37

PSI_LTD
Posted

nice work mate.

 

i've done a similar thing for my final year project at uni (back then it was turbocharging an lpg fuelled vehicle - back in 2006 there weren't many getting around).

 

from a scientific standpoint, how do you arrive at 300rwkw? have a think about what goes on in the engine.

to get 300 rwkw what flywheel kw does that require?

what driveline losses have you assumed?

what operating parameters have changed? eg. VE, bsfc, air density, change in fuel flow.

 

from that, you can infer what modifications need to be done. eg; since peak cylinder pressures have increased from xxx to yyy, the standard bolts stretch beyond specification. therefore we need 308 studs etc etc.

 

cheers

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matt_lamb_160    252

matt_lamb_160
Posted

Good work.

 

Couple of small things 1) by C series heads I assume you mean C1 or C2, a C2 head is for high comp and a C1 is reasonably high as well. Large chamber heads are E1 and early unmarked heads.

 

2) You also wrote inlet on the 1.6" valve by mistake.

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robbie    901

robbie
Posted

Top write up Marty McFly.. definitely 10/10 for a school assignment!

 

lol, Nice picture.. thats Daves XE at AFD, right next to Ants XD... Speaking of which, things look a lot different under there now, still off the road but one day she'll make a return

X-Taxi and mcfly94 reacted to this

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robbie    901

robbie
Posted

Can't remember his name but Jason built and tuned it, can be seen on tunnel visions Facebook page, makes over 300 at the wheels was at all for day

 

Different car, same colour though..  Wes tagged me in it and I had a double take, saw the number plates which gave it away straight away though.

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X-Taxi    472

X-Taxi
Posted

fantastic thread  great detail and very clean and tidy block !    those pistons and rods look tuff as.  i like the look of that 24 valve twin cam head!  i want one for our XE.  :)

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slydog    7,873

slydog
Posted

haha when i did my project i couldnt find a neat photo of a crossflow head.

 

20130705_133030_zps33840831.jpg

 

 

2012-01-21165351-1.jpg

 

These could have worked and if the pistons have enough CC would be a good turbo head I reckon.

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mcfly94    169

mcfly94
Posted

good read mate a fair whack of work in that

 

lets boost somthing :)

soon, just got to rebuild diff and then all will be focusing on motor and setup!

 

I've been thinking about boosting my wagon...

Well you have the info to do it! get to it!

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Mr Polson    10,214

Mr Polson
Posted

soon, just got to rebuild diff and then all will be focusing on motor and setup!

 

Well you have the info to do it! get to it!

$$$$$ and I should reallllllyyyyy finish the ute first......

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