Advice on Intake, Vacuum, Oil, Water ports with build setup

Mayor West

Well-Known Member
Hey friends,
I'm on the plumbing side of my build with the engine in and things starting to need connecting. I've put off a lot of these decisions because things evolve as I progressed and I didn't want to put myself in a corner with the wrong design.

Some notes on what's different about my build:
  • I am using 16AN fittings for the majority of the radiator lines
    • Normal hoses at the engine then connecting to adapters to get to AN through the frame tubing
  • I have an S252 turbo with a ZZP T3 manifold
    • There are no water lines
    • There are only oil lines
  • I have an external GFB 38mm waste gate
    • I intend to use the factory boost control solenoid if possible
  • I do not have the DF air/water intercooler, I am running an air/air intercooler.
  • I have an atmospheric venting BOV, I believe this requires a blow-through MAF but I am not sure on the specifics
  • I plan on running 93 octane with the stock fuel system
  • My downpipe has two O2 bungs and I plan on eventually running a wide band when I get to that point.
    • No cat
    • No muffler
    • Waste gate vents to atmosphere
I wanted to ask a few questions and make sure my assumptions/concerns are set straight:
  1. Since my turbo doesn't have coolant lines:
    1. I need to plug the two ports on top of the radiator inlet on the head... there's a two-in-one fitting, should i remove this dual port and plug it?
    2. I need to plug the side port on the thermostat housing that used to go to the K04. Threaded plug for this as well.
  2. Since I am not using the DF supplied intake pipes/etc for the intercooler, what ports do I need to add and for what?
    1. My donor came with a K&N intake pipe that I'm going to modify to reuse the MAF section. I think it has a vacuum line port on it as well but I'm not certain of its location or if I'll be able to reuse it.
    2. ZZP's custom tune section asks for the location of the MAF for tuning purposes, what am I likely to end up going with given my options?
  3. Regarding the MAF and the atmospheric BOV, what are the do's and don'ts for this? I believe the tune can accommodate for a blow-through MAF but I am not certain. I've also been told that I can run without a MAF if tuned for it. Thoughts? Pros/Cons?
  4. With a maximum power goal of no more than 380-400ish rwhp (regardless of mods, that's as high as I'd care to go)
    1. Is the 3 bar map sensor necessary?
    2. Are the Opel injectors necessary?
  5. Since I am using an external waste gate, can I still reuse my factory boost control solenoid as long as its tubed up correctly?
  6. Since I don't have the stock turbo, can any open ports be avoided, such as on the valve cover?
  7. Should I run a catch can?
Seeing what I'm working with above, do you have any thoughts/advice/etc for me? This isn't my first rodeo in building a car but it is my first pieced together turbo build with everything randomly selected rather than coming together as a kit. I am comfortable with what I've gone with but I want to make sure I don't make any mistakes if I can help it.

Thanks everyone for any advice/help!

Also, I do not plan on tracking this build. That's not the type of driving I'm going for. This is a nice-weather "just-for-me" sorta car. I'm not shooting for peak performance or top-of-the-line specs. I only upgraded the turbo because my stock compressor contacts the housing and I enjoy the build process, so a custom setup is a bonus for my pleasure. That being said, I don't want to do anything incorrect or set myself up for disappointment, failure, or future financial hardships due to something I could have avoided earlier in the build.
 
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OptimizePrime

Well-Known Member
  1. Since I am not using the DF supplied intake pipes/etc for the intercooler, what ports do I need to add and for what?
    1. My donor came with a K&N intake pipe that I'm going to modify to reuse the MAF section. I think it has a vacuum line port on it as well but I'm not certain of its location or if I'll be able to reuse it.
    2. ZZP's custom tune section asks for the location of the MAF for tuning purposes, what am I likely to end up going with given my options?
  2. Regarding the MAF and the atmospheric BOV, what are the do's and don'ts for this? I believe the tune can accommodate for a blow-through MAF but I am not certain. I've also been told that I can run without a MAF if tuned for it. Thoughts? Pros/Cons?
  3. With a maximum power goal of no more than 380-400ish rwhp (regardless of mods, that's as high as I'd care to go)
    1. Is the 3 bar map sensor necessary?
    2. Are the Opel injectors necessary?
  4. Since I am using an external waste gate, can I still reuse my factory boost control solenoid as long as its tubed up correctly?
  5. Since I don't have the stock turbo, can any open ports be avoided, such as on the valve cover?
  6. Should I run a catch can?
Seeing what I'm working with above, do you have any thoughts/advice/etc for me? This isn't my first rodeo in building a car but it is my first pieced together turbo build with everything randomly selected rather than coming together as a kit. I am comfortable with what I've gone with but I want to make sure I don't make any mistakes if I can help it.

Thanks everyone for any advice/help!
Pick up HP Tuners and go Speed Density and run without a MAF or catch-can (put a breather on one of the ports on your VC and plug the other port). Going SD you can run your external BOV without any issues as well. So, no intake ports and no maf means you'd basically just have a filter on the compressor (or not).

You'll want a 3Bar map sensor for anything over 15psi. You'll see if you need injectors in HP Tuners looking at the injector duty cycles while in full boost.

Your biggest gain from a catch-can is going to be taking your PCV off the intake mani external > catch-can > valve cover. Honestly I'd just clean the valves every 30K miles.

Also, get a wideband broskie.
 
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