Procharger Stage 2 Install

[Phils15GT]

Were you the guy at Lebanon Valley with the Ruby Red car Weds night?

Yeap. That was me.

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[royo]

Beautiful car man!

 

[z06psi]

I will be installing the 11-14 intake and the kit starting tomorrow morning.

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[Phils15GT]

I will be installing the 11-14 intake and the kit starting tomorrow morning.

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Awesome! Let us know how it goes.

 

[gqneon]

I will be installing the 11-14 intake and the kit starting tomorrow morning.

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Same here. You doing your own tuning or remote, I've lost track.

Tapatalk spelling errors inside!

 

[z06psi]

Same here. You doing your own tuning or remote, I've lost track.

Tapatalk spelling errors inside!

Lund is doing it. I will get the physical stuff done by Sunday but won't get the tune done until Monday/Tuesday.

 

[gqneon]

Lund is doing it. I will get the physical stuff done by Sunday but won't get the tune done until Monday/Tuesday.

I've got my base tune from him to do my baseline logging, my manifold just showed up with some new harbor freight goodies. I should know at least of the surging is gone even on this tune though by tonight or Saturday.

Tapatalk spelling errors inside!

 

[gqneon]

zo6psi and I have both been busy today. Looks like we both got our 2011-14 manifolds installed. A little dremel tooling for fitment, a little dremel tooling for flow improvement, and a TON of room now behind the manifold and firewall from all that IMRC shit being gone. Seriously. I can reach my arm straight down there now.

I'm working on getting my base tune in and I'll do some idle, step and cruise logs for Lund and see where this attempt has landed me on the "no more surge" campaign.

That harness behind the manifold and under the manifold - PITA. So glad all that stuff is gone.

There's a 3/8" or 1/2" plastic piece on the back of the 11-14 manifold that looks like it ought to be a hose connection - but I tried to blow and / or suck air through it and I think it's just a closed off piece of plastic. I was going to cap it to be safe in case, but does anyone know what that 1 piece of plastic is or what bolts to it on the 2011-2014 5.0's?

Would be nice to know.

Now to see if I made any vacuum leaks.

:cheers:

PS, guess which is the 15...

 

[gqneon]

Yup - I had a small vacuum leak and shored it up correctly, and will look for a proper y instead tomorrow when stores open. Otherwise it's just a base tune, the trims need some adjusting but it idles, albeit just a tad rough. It tossed a O2 stuck rich code, but that was right when I started idling after shutting it down with a vacuum leak.

That thing on the back of the manifold - with the engine running I put a thumb over it and nothing - I think it's just a mounting point for something or maybe it dead ended a hose or something on the 11-14's.

I cleared the code and ran a 5 minute idle log with no codes.

It feels ok, going to run it up to a parking lot to do cruise and idle stepping logs so my neighbors don't call the cops at 1130 at night. Wish me luck.

 

[Travis@boostworks]

That's the brake booster port for the F150. It's not punched out on the Mustang.

 

[cp5899]

I'm not sure what the imrc is, but I'm gathering its some sort of internal intake flap. Is this what people are having issues with on the tunes? Causing the surging in the rpm range? If they are a flap in the intake track can they not be removed?

 

[gqneon]

That's the brake booster port for the F150. It's not punched out on the Mustang.

Perfect - thanks. That makes sense. Saved myself a $0.50 cap based on that, checks in the mail!

:cheers:

 

[gqneon]

I'm not sure what the imrc is, but I'm gathering its some sort of internal intake flap. Is this what people are having issues with on the tunes? Causing the surging in the rpm range? If they are a flap in the intake track can they not be removed?

I don't know of an IMRC delete kit so a couple of us went this route or the boss manifold route to see what happens.

But yeah - what I've learned / understand is that it's a vacuum / load sensitive pair of servos mounted on the rear of the 15 manifold that open and shut intake runner flaps across all 8 intake runners incrementally based on what the PCM tells them to do. The theory is that they can be commanded to do "x," but under boost may be doing "y" or nothing instead. On an NA motor, I don't think it makes any difference except probably better low end torque as it was designed to make.

Turn up the pressure in the manifold, at least with a ProCharger, and depending on your tune, it is surge city. Results and experiences seem to vary. Now that I've removed the IMRC with a prior model-year intake, and I'm running a (base) IMRC deleted tune, I can immediately tell that the surging is a 2-part issue. Part 1 is the IMRC flaps - they do what the PCM tells them to do, not always what you expect them to be doing. Like say, if you blip the throttle to feather the gas/clutch at low speed from a stop and all of a sudden you about stall the engine. Intermittently. (Disclaimer - I've never stalled this car out in 5,000 miles lol)

Or worse, and most noticeably, when you're at that threshold between the BPV being open or shut (a few inches of vacuum until that first pound or two of boost) where it "surges" ahead then falls back on its face, repeat, repeat, repeat. That is a byproduct of the BPV in this design I feel.

What I found tonight is that even though the engine will still surge in that vacuum/boost twilight zone, without IMRC there to interfere in a positive or negative way, the surging is much less pronounced. One hardware component (the BPV) is not fighting with another hardware component (IMRC) as to how much or how little air charge should be getting stuffed into the cylinders.

I found the surging had to be almost introduced intentionally tonight, as opposed to "Christ, how embarrassing, I have to go more than 25% throttle in public and have everyone nearby hear my engine hunt and race and the BPV open and shut 10 times" mode.

We'll see how the tuning goes without IMRC but I've got my fingers crossed, and I'm really curious to hear from z06psi about his install and initial impressions with his base tune.

:cheers:

 

[z06psi]

Well I am almost there. I will finish up tomorrow. My PCV setup will be old school. The two throttlebody ports will run into the manifold block that comes with the Procharger and then route to the brake booster only since it has a check valve in it. If I ever take the manifold off again I will knock out that back port and use it. That would be the cleanest way to run that line and just loop the two TB ports.

The two valve covers will run down to the Procharger inlet. The passenger side will run into a catch can mounted up higher. I am only at 250 miles and there was a teaspoon of oil in it already.

Lund sent me my base idle tune with the IMRCs deleted as Beefcake told him I was going this route. We will see.

Two issues with the Procharger kit.

Belt was two sizes too short. The belt sent was a K080653 even though Procharger marked it K080655 with their own sticker. WTF? Why would they put a different Gates number on it? So I ended up buying a K080660 which I think is still 1/4" too short but it is two sizes larger then what was sent. ( I am running a 4.5" pulley off the bat)

The 90 degree elbow on the passenger side intercooler connection. Too short of a leg into the intercooler. I want a new piece and I will be contacting them about it. I stretched it but I am not confident of it holding cause there is not a positive rib on either side of the intercooler.

Those are the only two things so far but I have not ran the car yet.

 

[gqneon]

Well I am almost there. I will finish up tomorrow. My PCV setup will be old school. The two throttlebody ports will run into the manifold block that comes with the Procharger and then route to the brake booster only since it has a check valve in it. If I ever take the manifold off again I will knock out that back port and use it. That would be the cleanest way to run that line and just loop the two TB ports.

The two valve covers will run down to the Procharger inlet. The passenger side will run into a catch can mounted up higher. I am only at 250 miles and there was a teaspoon of oil in it already.

Lund sent me my base idle tune with the IMRCs deleted as Beefcake told him I was going this route. We will see.

Two issues with the Procharger kit.

Belt was two sizes too short. The belt sent was a K080653 even though Procharger marked it K080655 with their own sticker. WTF? Why would they put a different Gates number on it? So I ended up buying a K080660 which I think is still 1/4" too short but it is two sizes larger then what was sent. ( I am running a 4.5" pulley off the bat)

The 90 degree elbow on the passenger side intercooler connection. Too short of a leg into the intercooler. I want a new piece and I will be contacting them about it. I stretched it but I am not confident of it holding cause there is not a positive rib on either side of the intercooler.

Those are the only two things so far but I have not ran the car yet.

Install is looking good!

I also had BOTH of the initial problems you had with the ProCharger kit. I called them about the belts and ended up buying my own when they said they were correct. I had to buy belts 1.5" longer to work.

Do yourself a favor and DONT RISK IT with the passenger side intercooler outlet hose. I did. I towed it home from the highway the next day and had to tear the bumper back off to do it right with non-ProCharger parts. I used a silicone hump hose and aluminum coupler to mate the original PC piece.

Funny how both of these same problems happened to 2 customers half a world away. I used 6-rib belts from the autoparts store to find a length that would fit and then bought 8-rib belts online.

You'll get it sorted. But it's nice to see I wasn't nuts when they told me "it's worked for everyone else."

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