8/6/2019 Budget Turbo Build

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My TURBO M800 MPFi -

While working on the carb Maruti 800 turbo setup a few years back, I decided to buy anMPFI M800 and turbo-charge it someday. Later, bought myself a stock MPFI 4 speed M800and subsequently started collecting the necessary turbo bits. The goal with this setup issimilar to the my Baleno turbo build - to be fun, reliable daily driver. The only thing different

here is I wouldnt mind pushing/boosting it a bit more (M800 parts being not as expensiveand are easy to come by).

Though I have my Turbo Baleno, I wanted something smaller, capable and cheap M800. Over the past year I picked up the following BOV, couple of intercoolers, Swift dieselTurbo and few accessories. Then I came across a slightly larger MHI turbo and decided to dothe build with it. So now that I've most of the basic hardware needed to boost my M800,lets move onto the actual build thread or rather prep thread.

One of the initial problems (that worried me much) - very tight space for the turbo & ex-manifold. The oil filter jutting out in the front is a problem to have a the turbo hang belowthe manifold. Placing the turbo above the manifold may cause heating issues for the sparkplug wires etc. since it exits very close to the turbo/exhaust manifold.

Now comes the shopping list and running errands Listed out most of the hardware etc

needed for the build and started shopping.

1. Turbo ex-manifold - flange plate & exhaust flanges Gas cut & machined.2. New stud/bolts for turbo exhaust manifold3. Thick MS pipe (45 & 90 degree bends) 1.25 inch dia for fabricating ex-manifold.4. Copper sheet for cutting out turbo/ manifold gasket.5. 4 Bolts were machined and used in the Banjo setup for oil and coolant supply line. 6. 2MS pipe (full length) for fabricating the exhaust.

Started work on the car on a Tuesday morning.

1. Started by taking out the bumper, grill etc.2. Dismantled the stock ex-manifold and exhaust pipe.3. Temporarily mounted the turbo to the best position possible.4. Ex-manifold MS pipes were routed according to the turbo position & tack welded5. Removed the turbo ex-manifold and got it TIG welded.6. Oil and coolant lines & accessories were modified/fabricated to suit the build7. Got the 2MS pipe cold bend cut appropriately and used for exhaust system.8. Fixed the TRUST intercooler at a suitable/chosen position.9. Routed the intercooler plumbing from the turbo.10.Routed the intercooler plumbing to the intake manifold.

The build was almost done by Friday. Saturday was the final fitting and rechecking for leaks

etc. And sure enough there was a leak oil leaking at the banjo bolt at the turbo oil supply

source (probably because of a faulty machining of banjo bolt). It was fixed temporarily.

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The car cranked up just fine. Had a short drive to check how it felt. The turbo kicked in

quite late as compared to my Turbo Baleno but I guess it was not getting the right amount

of fuel under boost. Soon after, it felt like the fuel supply being cut off (maybe because of

the MAP sensor boost issue) but there were not CEL, unlike Baleno when on boost.

I have been out of the country for a couple of months now. The next step is

1. Have an ECU in place to sort out/optimize fueling and ignition maps.2. Fabricate a new part for the oil leak at the turbo oil supply source. 3. Upgrade to Baleno Injectors to meet fueling needs.