Phase 8: Turbocharging The Rear Engine 
Now we turn our attention to boost cooling. After many, and i mean MANY, options - we decided that the best option is to use a water-cooled intercooler, also knows as chargecooler.
Now we turn our attention to boost cooling. After many, and i mean MANY, options - we decided that the best option is to use a water-cooled intercooler, also knows as chargecooler.
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This is a Peugeot 605 / Citroen XM 2.5 Turbo Diesel chargecooler but it is virtually the same as a 405 T16 one, bar the turbo badge. Oh and it's a lot easier to come by as well as much cheaper ;-).
This is a Peugeot 605 / Citroen XM 2.5 Turbo Diesel chargecooler but it is virtually the same as a 405 T16 one, bar the turbo badge. Oh and it's a lot easier to come by as well as much cheaper ;-).
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Boost and water connections.
Boost and water connections.
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Close-up of the core inside.
Close-up of the core inside.
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This is a water radiator we'll use for the chargecooler.
This is a water radiator we'll use for the chargecooler.
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It's a Zastava 750 item, like our rear bonnet louvres :-).
It's a Zastava 750 item, like our rear bonnet louvres :-).
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It seems that on our car, if it's not a Peugeot part (with the exception of the Subaru turbo), it's a Zastava part - Yugo's radiator fan.
It seems that on our car, if it's not a Peugeot part (with the exception of the Subaru turbo), it's a Zastava part - Yugo's radiator fan.
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After figuring out where to actually install the radiator (the decision is fit it in the space behind the right side-air-intake), we got the inlets and outlets to suit the mounting space and configuration.
After figuring out where to actually install the radiator (the decision is fit it in the space behind the right side-air-intake), we got the inlets and outlets to suit the mounting space and configuration.
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Fan fitted inside the shrouding and outlet modified for the last time.
Fan fitted inside the shrouding and outlet modified for the last time.
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The last big piece of the chargecooler puzzle - a water pump. It's a FLOking marine fresh water pump made by Leisure Accessories.
The last big piece of the chargecooler puzzle - a water pump. It's a FLOking marine fresh water pump made by Leisure Accessories.
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The specs - hopefully it will perform good enough in our application.
The specs - hopefully it will perform good enough in our application.
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We finally got some larger injectors - keeping the Peugeot theme, they're 405 T16 (Magnetti Marelli IW430) injectors. Said to be in 390-440cc region and kindly lent to us by Goran.
We finally got some larger injectors - keeping the Peugeot theme, they're 405 T16 (Magnetti Marelli IW430) injectors. Said to be in 390-440cc region and kindly lent to us by Goran.
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They are shorter than Mi16 Weber injectors though...
They are shorter than Mi16 Weber injectors though...
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...so the fuel rail had to be modified (to sit closer to the head).
...so the fuel rail had to be modified (to sit closer to the head).
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Swapping the fuel rail and fitting the 405 T16 injectors.
Swapping the fuel rail and fitting the 405 T16 injectors.
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The next step is to create a base N/A map for the new, larger injectors, with added load sites above 100 kPa and fueling will be ready for boost. Ofcourse, we'll have to properly map it over 100 kPa when the turbo is actually on and boosting :-).
The next step is to create a base N/A map for the new, larger injectors, with added load sites above 100 kPa and fueling will be ready for boost. Ofcourse, we'll have to properly map it over 100 kPa when the turbo is actually on and boosting :-).
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