'08 BL9 2.5i. '91 BC6 awd and turbo conversion.

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Re: '08 BL9 2.5i.

Postby bigBADbenny » Tue Mar 02, 2021 4:21 pm

rexhunta wrote:
bigBADbenny wrote:Here’s that knock sensing ignition retard box I may have mentioned.

http://www.jandssafeguard.com/


Uh no you haven’t sorry. But definitely a good product


Its more affordable than most engines or rebuilds, potentially a good failsafe for those who like tuning to the edge :P
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Re: '08 BL9 2.5i.

Postby rexhunta » Sat Mar 06, 2021 7:04 pm

Wasn't planning on going to the shed this weekend, but amazing how plans change when the mother in law randomly visits, and then springs shes staying for a few days.....

So got the coils mounted up, wiring harness extended on that side for them. Extended the harness for the rear 02 sensor, and got the main harness that comes through the firewall rerouted so it's away from the turbo.

Reconbobulated the air intake pipe, i'm still toying with it, I wasn't entirely liking it, so still messing around with that.

Ordered some new tie rod ends, replaced the seal on the p/s pump, replaced the passengers cv boot as that had split.
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Re: '08 BL9 2.5i.

Postby nvmylh » Tue Mar 09, 2021 8:09 am

Sounds like you got some decent work done!

Do you have a picture of how you cleared the crossmember with your up-pipe? I thought it was pretty much impossible to squeeze anything through..
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Re: '08 BL9 2.5i.

Postby rexhunta » Tue Mar 09, 2021 12:15 pm

I used the gt one that had the notch on it ? I just went to the wreckers and asked for the turbo liberty crossmember
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Re: '08 BL9 2.5i.

Postby rexhunta » Sat Mar 20, 2021 10:06 pm




So today I had my first start up, as per video. Excuse all the smoke coming off, painted pipes, stainless headers and greasy fingers etc.

I let it idle to temp, and then shut it down. I have a oil leak from the oil drain somewhere, so that's future Petes problem at this stage.

My other main concern is, I have my breather incorrectly installed, and I don't quite understand how to set it up properly, so time for more net searching and taking in how the crankcase itself breathes and gets it's own fresh air in.

Hopefully I work it out soon.
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Re: '08 BL9 2.5i.

Postby bigBADbenny » Sun Mar 21, 2021 11:58 am

Here’s the basic diagram of pcv pipes & valve.
http://opposedforces.com/parts/legacy/e ... tration_2/

And on the intake manifold... actually all parts here are pre 08 so maybe ignore this depending on your build date.
http://opposedforces.com/parts/legacy/e ... tration_4/

The cam covers with head breather ports:
http://opposedforces.com/parts/legacy/e ... tration_2/

The block showing the sump breather near #3:
http://opposedforces.com/parts/legacy/e ... tration_2/

That looks to be about it for my08 2.5i.

The rest is joining the dots, but from a brief look it appears that the plenum serves the purpose of balancing the head breathers, perhaps the sump breather returns to the intake manifold via the pcv.

What’s your setup?
Pcv delete, single or dual can?

Ps: bravo! That’s a major milestone :good:
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Re: '08 BL9 2.5i.

Postby rexhunta » Sun Mar 21, 2021 12:20 pm

bigBADbenny wrote:Here’s the basic diagram of pcv pipes & valve.
http://opposedforces.com/parts/legacy/e ... tration_2/

And on the intake manifold... actually all parts here are pre 08 so maybe ignore this depending on your build date.
http://opposedforces.com/parts/legacy/e ... tration_4/

The cam covers with head breather ports:
http://opposedforces.com/parts/legacy/e ... tration_2/

The block showing the sump breather near #3:
http://opposedforces.com/parts/legacy/e ... tration_2/

That looks to be about it for my08 2.5i.

The rest is joining the dots, but from a brief look it appears that the plenum serves the purpose of balancing the head breathers, perhaps the sump breather returns to the intake manifold via the pcv.

What’s your setup?
Pcv delete, single or dual can?


ATM I just joined everything that went to the original plenum and then a single port into the intake side of the turbo. I definitely know this is incorrect now :lol:

I've just grabbed a single catch can this morning that has 3 ports, I will go through a few more diagrams including what you have posted up and have a look.

Originally the 2 head breathers went into the intake box that's attached to the throttle, and what looks like a pcv from the block went into the front of the box as well, and on the side of the block breather is another that goes straight to the plenum.

Pete.
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Re: '08 BL9 2.5i.

Postby rexhunta » Sun Mar 21, 2021 7:05 pm

Thank heaps for those diagrams Benny, I has switched the 2 sump ones around backwards and filled the intake with oil. Once I flipped them back all sorted, I must of had the 2 hoses off and in my haste didn't check my photos I took when I pulled the intake apart couple of months ago.

I didn't install the catch can but mounted the gauge etc on the column, during the week when I have 5 mins i'll jump under and find what's seeping oil underneath, then throw the bonnet back on and go for a test drive with the gate disconnected like we usually do to check the rest for leaks and any other issues.
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Re: '08 BL9 2.5i.

Postby Yowie » Sun Mar 21, 2021 8:01 pm

Good work on the first start with the new configuration.
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Re: '08 BL9 2.5i.

Postby bigBADbenny » Mon Mar 22, 2021 6:57 am

Based on our exploration of the 2.5t pcv system, it looks like a simplified for n/a version.

So heads and central crankcase breather are for circulation and blow-by balance, the primary source of crankcase vacuum would be the sump breather.

If keeping the pcv valve, you might want to use cans on a unified balance return to inlet and another for the pcv, the latter having the most vacuum to help drain the turbo, with a three way pre pcv returning to the inlet.

If deleting pcv, I’d say delete central crankcase vent, heads & sump breather to the catch can to the inlet, pre turbo.
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Re: '08 BL9 2.5i.

Postby rexhunta » Tue Apr 27, 2021 10:30 pm

I am now running the dual catch can setup, i've got the heads together into 1 can recirc'ing back into the intake, and the other can I have the 2 coming from the block itself venting to atmo, you can feel the pulsing at idle on the breather on top of the tank.

My vacuum has now evened out and the idle is a lot better.

Do these ECUs self learn to a slight degree like the nissan ecus ? I've had it unplugged and replugged back in, it seems a lot fuelier on idle and driving, but doesn't seem to pinging. I do have a leak at 1 of the flanges, I think it's the chinese shitty slip joint. Bit more investigation into that later on.

Also still waiting for all the fluids that I dropped onto the heat wrap to finally burn off :lol: Hopefully soon it'll stop smoking after a drive around the block. I need to get the wideband on it and give it a check. It's still sitting at 3 psi which I am happy with in what the state of the car is.

I can forsee at this point a headgasket change though, at 160,000kms I think it's still got the OEM shitters in there.

Pete.
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Re: '08 BL9 2.5i.

Postby nvmylh » Wed Apr 28, 2021 9:31 am

Your engine has a maf sensor so venting the can to atmosphere is going to upset that. I think you'll need to plumb that can back in after the maf sensor.

Got any pictures??
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Re: '08 BL9 2.5i.

Postby rexhunta » Wed Apr 28, 2021 12:06 pm

Will do tonight.

From what I could see the ej25 only has 1 entry into the top of the block itself, and on mine this has a y piece with the valve on 1 side of it. I’ve got the intake plenum itself blocked off atm on the output side.

Will definitely grab photos tonight.

And correct in the maf, currently the heads return is behind the maf before the turbo inlet.
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Re: '08 BL9 2.5i.

Postby rexhunta » Wed Apr 28, 2021 8:05 pm

nvmylh wrote:Your engine has a maf sensor so venting the can to atmosphere is going to upset that. I think you'll need to plumb that can back in after the maf sensor.

Got any pictures??


Just excuse the coilpack wiring, i've got it out as i've been check voltages on stuff.

Image

Image

LH can is the heads back into the inlet pipe.

RH can is both block breathers. The original pipe off the plenum to the pcv on the block y piece is blocked off.
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Re: '08 BL9 2.5i.

Postby Yowie » Wed Apr 28, 2021 9:38 pm

If there is (or can be) a serviceable PCV on the inlet manifold (after the throttle), you could replicate the factory style crank gas routing by:

- running a hose from the top of the crank catch can to a T-piece;

- running a hose from one side of the T-piece to the PCV; and

- running a hose from the other side of the T-piece to the pre-turbo intake pipe.
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