Been working away at the ambo when I could in between other projects. Hooked up my leak tester to the exhaust and everything was airtight. Took it for a quick drive and it has more umph than it ever has, but intake hat is now leaking profusely. I needed to pull the turbo off to replace the leaking grommet, so tore into it to try and get a better alignment with the intake to hopefully fix the last boost leak. Turbo flange gasket wasnt leaking, but replaced it while I had it off.
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Massaged the firewall even more to get a bit more clearance for the back of the turbo, you can see where it has been rubbing. Replaced the grommet with one directly from banks, super pricey but should work as designed. The banks grommet had notably less lip to grab the pan but fit the od of the drain much tighter.
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Got the turbo and everything back on, intake hat was closer to lining up but the turbo still hits the firewall limiting how much I can clock it. Im currently getting a low profile intake hat made that will work much better for this aplication, Ive been working on the design for awhile and this would be a perfect aplication to use something like this so first one will be getting donated to the ambo, then finally should be rid of the boost leaks. Never have had some much fitment issues with a turbo kit in a truck, theres not much room on an ambulance. Waiting on the intake hat to be done, I moved onto electrical.
When I had the headlight switch out I noticed the connectors were very loose. The stock plug had been replaced by a bunch of spare wire and various sized spade connectors.
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Once I got my replacement pigtail in, I cut back to where the stock harness had been spliced into then hooked it up to the replacement connector. Everything is pinned and color coated like original, and shouldnt have any more intermittent power supply issues for the lights.
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When I last had the ambo, I upgraded to this monster derale pan to help with cooling. Its a sweet piece with passages for air pass through the pan to pull heat, all metal construction, and ports for temp sensor and drain. Its a big improvement from stock, buts a lot heavier than the little stock pan. The pan was leaking, and six bolts were gone with threads with them. I tapped every bolt hole to 3/8-24 which is a good fine thread. No more leaks once I got the e40d topped back off.
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Currently just waiting on the intake hat to be done, in the meantime I have been narrowing down the last of the electrical issues. Left turn signal turns on rear hazards, and brakes turn on front right turn signal. I believe I have this narrowed down to a grounding issue for the rear tailights, just need some time to explore it.