Need a bit of a quick answer here as car is in bits on drive and it's going to rain!!! And I want it back on the road.

Had the inlet manifold off to fit insulating spacers, and fitted new TD05-20g at same time.

Now the problem - the o/s fuel rail, no.3 position ( where the OEM fuel pressure reg used to live ) is pressing on the cover of the turbo, and won't allow the manifold to line up with bolt holes etc. ( 1/2 inch out ). Fuel hose also rubs against front cover, so not going to fit really!


How have other TD05-20G users, with aftermarket fuel pressure reg ( FSE 1:1 here ) sorted this clearance?


I noticed the o/s fuel rail is longer after the injector than the other side in this position.

Tried to swap fittings from one end to other to gain 2cm room, but the fuel reg adaptor has an o-ring on the adaptor that enters the fuel rail, but other ends of the rails have o-ring in rail. So can't simple swap over.

Would it be possible to swap n/s and o/s fuel rails? My next trick to attempt!

Does anyone still do modified fuel rails ( Carl ? Legacy Turbs ? ) for this problem?
(Parallel fuel rail feed and return, but simple T-piece and hose job! ).


Thanks

N

 

Had a similar prob (just read your pm)

i did not fit any insulators so manifond prob closer to 20g than yours.
In fitting the SX reg, you get a machined alum alloy fitting to substitute for the stock reg.
It had an elbow connection which I rotated to clear the housing (only just) and made-up a short connection hose fron it to the fuel rail (remember mine is parallel mod rials) and it all just squeezed in
There are pics on my project pages, towards the front if you can find it.
Very very tight as I recal.
Graham.

 

hacksaw and chisel are your new best friends

There is plenty to come off the 20g compressor cover.

 

Might help a bit?

ps Paul: Your new web site is great!

Graham

 

Cheers Paul, the bit in the way is flat, may have been machined already?
Bit wary of grinding / hacking away!
With the manifold insulators on the fuel return is just across the turbo inlet now! Bit of bending of fuel rail outlet pipe once swopped ( see next post! ) aimed it under the inlet and new fuel rail position allowed manifold to fit OK and fuel pipe run OK just under inley.


I'll post up the next problem with my install soon!

Neil

 

Cheers Graham.

That adaptor look identical to the one that came with the FSE fuel reg kit! Same problem too!!
I thought about trying to rotate the brass fitting 90 degrees in the ally block, but it was well tight, and I was concerned it may leak if I backed it off a 1/4 turn. Other idea was to fit ally block to 180 degree out on fuwl rail end and feed fuel hose away from turbo and back to fuel return in between manifold runners.
Yeah, I have basic parallel fuel rail set up using T-pieces, so a bit of flexibility on pipe runs ... think I'll extend the current pipe run soon and pull it away from turbo.

Solution I suceeded with, although it was clear of turbo cover it left the return fuel hose across lower part of turbo inlet! I swapped over the fuel rails from each side, as n/s rails are shorter after the injectors, and all dropped into place reasonably easily. A bit of bending of the remaining metal tail of pipe on the return away from turbo inlet, and viola, job's a good 'un.!


Next problem .. using 90 degree inlet system on FE turbo!

I'll be back ...

 

does this mean you have a tdo5 for sale then Neil?

 

Fraid not Jay, it's to be px'd with the good turbo wizard Andy F.

Unless you wanna pay more than the px ... then I'll pay Andy money instead!!

Be interesting to see what she's like when mapped ... seems more mid range go already ( but limiting revs and boost until mapped )

 

You won't be dissapointed...
http://www.dropshots.com/day.php?use...9&ctime=044620
Graham

 

You should sell it to Andy D in work then he has no excuse to follow in your foot steps , hope it is all going okay speak to you tommorrow .
Still won't be as fast as a saloon !!

Mark

 

Cheers Mark, yeah, all going well fixed a few ( more ) problems that the car came back with post new engine, and fitted the oil gauge sensors that seem to have defeated 2 garages!!

Hope to get it mapped again this next week or so hopefully with the AVC-R boost controller /3 bar MAP sensor ( wanna buy a Hybrid controller ? ) and Z32 MAF. If Andy can fit me in ...

Was 363 bhp/325 lbft, guess more now!!! Once set up!!
I'll take you out for a spin once lunchtime!!

How's your saloon going!]

N