95 Voyager Turbo Part 2(?)

I've lost track of how many changes this think has had, but it's time to get it on the road again!
The previous thread is here => http://www.turbo-mopar.com/forums/sh...rbo&highlight=
Though I think a lot of the pictures got mangled from Photobucket.
Here’s a link to the album if you care to take a look.
http://s408.photobucket.com/user/Str...oyager%20Turbo

Well, I stopped driving the van due to it smoking pretty badly. I was pretty sure it was a valve guide or a valve stem seal issue. Then I decided to take it out for a spin and ended up over-spooling the turbo. Now’s as good of a time as any to replace the head and turbo.

Sad dusty van

http://i408.photobucket.com/albums/p...psw0m6op2k.jpg

I don’t think the shaft of the turbo is supposed to come out that direction.

http://i408.photobucket.com/albums/p...psnriihthv.jpg

Bleh! I got a lot of miles out of the free, home rebuilt, and not balanced turbo.

http://i408.photobucket.com/albums/p...psudzcsw2l.jpg

Yeah, I think it’s bad.

http://i408.photobucket.com/albums/p...psuub3qhvm.jpg

The manifold had a nice big crack.

http://i408.photobucket.com/albums/p...pslxzn4mou.jpg

Looks like I’m going to need a new EGT probe.

http://i408.photobucket.com/albums/p...psqztx5hoi.jpg

Turns out the previous machine shop had installed all of valve guides too low to the point where the valve stem seals had nothing to grab on to. I knew something looked fishy from the start, it should have never been installed. Here you can see the exhaust port on cylinder 3 was puking oil pretty well.

http://i408.photobucket.com/albums/p...ps6czlrywh.jpg

This should do nicely!
It’s a journal bearing t3/t4b with a 46 trim compressor wheel and F1-54 turbine wheel with the .63a/r turbine housing and a 2.5” swing valve. Thanks to Cindy @ FWD!

http://i408.photobucket.com/albums/p...psikppbml3.jpg

http://i408.photobucket.com/albums/p...psd5whnjqb.jpg

Got the replacement head back from the machine shop (a different one this time). I didn’t go too crazy with the port work. It’s mostly just matching.

http://i408.photobucket.com/albums/p...psf617f99h.jpg

Cleaned up a new manifold and port matched it to the turbine housing. Mike Holler’s article on Allpar had some good information. http://www.allpar.com/fix/holler/exhaust-porting.html

http://i408.photobucket.com/albums/p...psqrzhv7jh.jpg

Drilled it for a new EGT probe and replaced the studs I broke. I couldn’t find a decent price on the 10mm X 1.5 studs anywhere so I just bought a 1M piece of grade 8.8 all thread from Amazon for $8 with free shipping and cut it up.

http://i408.photobucket.com/albums/p...ps8lqiorup.jpg

Purdy

http://i408.photobucket.com/albums/p...psgxhxxl5q.jpg

It has sadly taken months to get to this point.
I used the Dorman 03411 exhaust manifold stud and nut kit and it worked great.

http://i408.photobucket.com/albums/p...psthgzkmgz.jpg

Hopefully it will run again this Saturday!

Looking forward to seeing the van up and running again!

Cool news!

Quote:

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Originally Posted by glhs727

Looking forward to seeing the van up and running again!

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When's the next dyno day? I'd like to get some hard numbers on this setup :evil:

Everyday is dyno day:thumb:

I thought it was a V6 turbo? I am loosing track of your vans, :confused:

It was originally a broken 3.0/3spd and we swapped it to 2.5/5spd.

Any suggestions for a guy thinking of doing a 2nd gen van turbo swap? I recently acquired a roached 89 5spd van. It really need rebodied. I was thinking of using a 2nd gen van because it should be easier to find a nicer doner.

2g uses a body control module to run all the gauges and interior stuff so if you want to have functional stock gauges you have to be able to read a wiring diagram and figure out how to reroute those signals.

I feel the easiest way to do it is to get a 2g TBI/5spd van, find a turbo SBEC, and add the additional turbo circuits to the TBI harness. What was done here was mixing an 89 SMEC harness with the 95 harness including PDC relay/fuse box and feeding all the signals through the stock BCM but out to a Daytona instrument cluster with 145mph speedo and factory boost gauge and retaining airbag functionality and all of that. Not the easiest approach but obviously it's possible.

The main reason 2g vans have rarely been turbo swapped is because there just aren't that many 'hobbyists' who are good enough with wiring diagrams and soldering to end up with a fully 'functional' van that doesn't have half---- or non-working stuff on it. If you're one of the ones who can, go for it!