An update...
Everything pretty much works. I've been driving around. I did about 60 miles since I filled the tank and it just moved off full. My gauge is optimistic, but that wouldn't have happened with the gasoline engine.
The cooling fans have never come on. Peak temp has been 191F.
I'm working out bugs then will do some more pics and writeups.
Here's the bugs.
Few questions in here are bolded and I'd welcome any suggestions!
1. Gearing. I got my trans re-geared .70 for 4th and 1.18 for 3rd. I'm kicking myself that I should have got 1.08 for 3rd. 1.18 is only an 8% overdrive from stock.
1st and 2nd gears are stock.
1st, 2nd, 3rd get a little buzzier than I'd like. I shift at about 2700-3000 in 1st and 2nd.
My solution is to increase my rear tire size from
edit: 25.5 inch diameter to 28 inch diameter. I'm looking at [FONT="]16" steel wheels and 215/70R16 or 225 tires[/FONT] This will give me a 10% overdrive and help 1st, 2nd, and 3rd.
The only issue is that it will make 4th taller as well. At 70 MPH, it'll put me at 2700-2800 RPM, not the 3000 RPM that people seem to recommend for happy EGTs. I'm planning on a Malone Stage 2 or 3 tune with stock turbo.
Any thoughts if the 2700-2800 RPMs will make a difference with EGT?
(P.S. for others doing a swap.. It is possible to go to a 15 inch wheel and then up to 31 inch diameter tire will fit.)
2. Vibrations. Things get a little annoying at higher RPMs (3000ish). I'm using the hydraulic mount on the rear and rubber mount on the front of the engine. The transaxle is suspended from the front mount only. (Note to others: losing the rear trans mount works fine!)
We're going to revisit the mounts. If the issue is on the front (non-hydro mount),
maybe I can use a hydraulic rear mount on the front? The dimensions are the same but it's meant to be pushed on by the torque not pulled.
If the vibrations are coming from the front (solid) trans mount, there may not be much that I can do. There's really no space there to do anything custom.
3. Noise. Inside, it's loud, especially at higher RPMs. I'm not sure how much noise is vibrations and how much is other stuff.
Any ideas on isolating where the volume is coming from?
I'm running a CAT only, no muffler. I could add a muffler? Other than that, I can get some sound-deadening panels and glue them in the cargo, rear-seat area.
4. Clutch actuation. The Kennedy Stage 2 Clutch takes a stronger left leg than stock. It puts more stress on the cable, clutch arm, etc. There's little bits of play in the clutch arm, clutch shaft bushing, and as a result, the clutch disengages very close to the floor.
I've got a new clutch arm and a bronze shaft bushing on order. These should take out a little more play and make the clutch a little more comfortable to actuate.
5. IAT. I've got a 7" fan mounted on a Saab Blackstone intercooler. The IC sits in the left rear of the engine compartment. It should be getting air from the vent above, but it's not sitting directly in airflow. I know it's helping, but it's not ideal. I'm hoping it's enough.
6. Oil Leaks. I've got at least one oil leak, probably two. I'm waiting to put the bus up on the hoist again to figure it out. Possible candidates are the oil pan and oil cooler. If the oil cooler is leaking, I'll upgrade to the bigger one. Any deals on a new one that you might see, please let me know.
P.S. to Jeremy, hoping to make the Dec 3 GTG later in the afternoon
Mark