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    Thread: My Turbocharged M800 MPFi

    1. #1

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      joeking's Avatar
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      My Turbocharged M800 MPFi

      While working on the carb Maruti 800 turbo setup a few years back, I decided to buy an MPFI M800 and turbo-charge it someday. Later, bought myself a stock MPFI 4 speed M800 and subsequently started collecting the necessary turbo bits. The goal with this setup is similar to the my Baleno turbo build - to be fun, reliable daily driver. The only thing different here is – I wouldn’t mind pushing/boosting it a bit more (M800 parts being not as expensive and are easy to come by).

      Though I have my Turbo Baleno, I wanted something smaller, capable and cheap to run around in – M800, it was. That makes it " Two boosted suzuki siblings"

      Over the past year I picked up the following – BOV, couple of intercoolers, Swift diesel Turbo and few accessories. Then I came across a slightly larger MHI turbo and decided to do the 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 below the manifold. Placing the turbo above the manifold may cause heating issues for the spark plug 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 manifold
      3. 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. 2” MS 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 welded
      5. Removed the turbo ex-manifold and got it TIG welded.
      6. Oil and coolant lines & accessories were modified/fabricated to suit the build
      7. Got the 2” MS 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.

      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.

      Click image for larger version. 

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      Last edited by joeking; 30th May 2011 at 15:19. Reason: pics

    2. #2

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      Another pic of Turbo manifold

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    3. #3

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      1st pic -Turbo & exhaust manifold bolted on to the car.
      2nd pic - View of the engine bay with the intercooler, plumbing etc in place.

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    4. #4

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      So informative, wat about zen ? Is it worth to go for a turbo job on 1.0 lt engine of zen's ? I mean, is it a hassle free setup after installment ? And wat about the ease of gettin it installed ?

    5. #5

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      Zen's G10B engine is quite a good engine to be turbocharged, but its often overlooked since G13B and G16's are available out there.
      The question wrt to the setup being hassle free - I dont have a straight forward answer to it. It depends on the quality of parts and hardware you buy and most importantly how well its put together. Besides this, the right kind of tuning (fueling/ignition) will allow the engine to run without failure or other issues provided the build as such has been done well.

      You may need a good tuner (or - someone who has enough hands on experience with setting up these things and tuning it). If you have access to some tuner or someone else good enough to this, getting it installed may not be all that difficult.

    6. #6
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      Nice work joeking!

      Why did you not try a top mount IC setup? And how is the IC getting the supply of air in the current setup?
      2002 Tata Indica DLS.
      2004 Suzuki Zen - A G13B eater.
      2005 Suzuki Baleno - India's fastest Naturally Aspirated Baleno timed on a drag strip officially!
      2008 Suzuki Swift VDi - The Rattle King.
      2011 Chevrolet Cruze - The Torque Monster.
      2016 Ford Ecosport 1.5 TDCi Titanium - The SQ Machine in the making.
      2017 Skoda Octavia VRS - A 400+HP corner craving machine!
      2013 BMW X1 - The RWD Sideways Machine
      2019 Polo GT TSI - The Commute Workhorse.
      2014 MOC SQ Pro Champions.
      Harmonixx Tuning - Importers for Audiofrog & Arc Audio/APR Tuning Authorized Dealers/Engine Remap Specialists for all makes/models.
      Dealers for Rainbow/Mosconi/Eton/Stetcom/Tru Technology/Blam Audio/Mobridge/Stetsom/Audible Physics/AIV/Gladen/Dampmat/Dr Artex Damping and more.

    7. #7

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      @mcl - TMIC required me to work on the hood and also needed relative slimmer IC. One other reason - The IC plumbing may have to be routed too close to the turbo ex-manifold. Besides I dont like the IC been seen outside the car. I dont have an air flow ducting in place right now. Plan on doing that later. But, for the most part the IAT is not that high with the current setup.

    8. #8

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      MHI turbo pics

      Posting a few pics of the MHI Turbo used in the M800 turbo build.

      Click image for larger version. 

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    9. #9

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      Finally got some time to fix the oil leak at the turbo oil source line. No more oil leaks.

      Now, I need to replace the ABS/plastic turbo plumbing pipe and with a fabricated metal one. I kinda knew that the plastic piece would give up !!

    10. #10

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      Posting a few pics of the engine bay.
      Build update
      1.ABS plastic intercooler - intake plumbing replaced with metal pipe.
      2.Turbo oil line banjo bolt oil leak fixed.
      Attached Thumbnails Attached Thumbnails Click image for larger version. 

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