Turbo 3100. What needs to change

[bkaab]

Well I think I have a TGP turbo setup a guy is going to get from Junkyard for me. What else do I need to change in order to run it? I have heard that you can't use the exhaust manifolds on a 3x00? I know I need to run a Map sensor that can read boost. Bigger fuel injectors I have an extra set of L36 and L67 injectors I can get a different PCM so I can tune it with DHP powertuner. And I will need to plum lines from the turbo to the oil pan.

[bkaab]

I am getting all the exhaust stuff, turbo and all the piping and thhe intercooler. That should be a good start to making a setup.

[WrathOfSocrus]

The 3X00 has D shaped exhaust ports compared to the round ports on Gen 2's like the TGP log manifolds. You should be able to grind out the shape as long as you are properly oriented (make sure the D shape fits the head and isn't upside down). The 3500 I believe has larger exhaust ports, compounded with boost and better volumetric efficiency, the TGP logs are rather undersized for the job. For a 3100 they should be fine. Check out the 'crossover' part that the turbo mounts on, as there may be cracks or leaks that would need repair.

As for the tuning side of things, you would need an OBD2 MAF setup or an OBD1 setup with 2 or 3 bar MAP to meter the air flow. http://60degreev6.com/forum/showthread.php/49720-hx40w This link is a recent thread with info that can help point you in the right direction.

[bkaab]

Thanks.

The cars is a 96 so I'm going to run a L67 map and get a pcm out of a 97 lumina or something.

[WrathOfSocrus]

Check out the end of the second page on that thread.

[bkaab]

Check out the end of the second page on that thread.

Very good info right there. Had no clue that the PCM would at weird to boost. So running a stock MAP and then tuning the MAF would be a good way to go.

[TGP37]

That's right, the MAF sensor will handle the fueling in boost. So long as you don't outflow the MAF. I hit up to 12psi and the MAF didn't max, but was close. You CAN get a 2-bar map but you'll need to change the table in the PCM with tiny tuners. Which means you need a BIN file of your PCM or get a hold of a DHP Tuner.

Turbo exhaust manifolds should be smaller diameter then N/A mani's. Reason is velocity, velocity, velocity. The sooner the exhaust reaches the turbo, the sooner boost can make more power. Which is why turbo mani's don't employ tactics like a N/A header would. An equal length turbo header would produce extra power from the equal lengths, but the smaller diameter/shorter pipe will hit boost sooner. Making the equal length mani less powerful then a typical turbo manifold.

I don't have the link but, A 500hp turbo did better with primaries smaller then the 300hp NA primaries. Dyno proven. They weren't much smaller but it shows how turbos need different principles in exhaust.

So don't worry about small diameter except mating to the D shape port.

If using the turbo manifolds from the turbo, make the D shape and blend back about 1-1.5". If making your own crossover/flange, do not use a much large diameter. Try to keep it just a hairline larger then the manifolds diameter.

For example, I have stock 96 manifolds and a custom crossover. I managed to start hitting boost around 2400 rpm in 2nd gear.

[bkaab]

Yepp Here's some pics of the difference. Ya wouldn't happen to have a pic of your engine bay/ the crossover ya made?

And comparison between 3100 and 3.1 head exhaust manifolds



And this is the 3.1 exhaust manifold with the 3100 gasket to show the difference in size.

[TGP37]

I have pics somewhere, but not on the laptop.

It was a stock crossover (so it fit perfectly) and the turbo was hung where I wanted it. I made cardboard pieces to simulate the steel pieces needed.

I did the crossover mod twice. Once with the auto trans (4t60e) and this time w./ the getrag282. So It will work for auto trans applications. The turbo will mount close to the 2-4-6 bank (front).

I'll post up pics later today, hopefully. Since your project is a 96 GP, same as mine, I can offer advise based on my trial and errors.

i.e.- The ABS pack makes it very hard to route the exhaust from the turbo. So use a 2-2.25" downpipe or remove the ABS pack.