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lookforjoe

2012 C30 T5M/Warning!-Fiat content!!

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Was wondering if this was coming together before Carlisle.

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Did you leave the subframe in place when you removed the transmission?

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8 hours ago, andyb5 said:

Did you leave the subframe in place when you removed the transmission?

I did. Pain in the neck coming out, but going back in, I removed the heater hose of the back of the motor & rotated the transaxle so the diff pointed straight up, then rotated it around to align. Definite PITA on a jack with wood chocks strategically placed while jacking to prevent it falling off..

 

Dropped the turbo today.

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Turbosmart dual port CBV base orings suck, emailed Don about this

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K16 going in. Added a blanket to the housing, and also a SS bung to feed my dual boost gauge

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RS oil cooler in

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Trans back in

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Hopefully wrap it up tomorrow afternoon.

In Fiat related news, the heater valve went this morning. Replaced it with one of the metal/plastic style 700 valves.

3E1FE72E-C189-4E3C-B23B-B42728ED0D22_zps

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Axles are re-booted & re greased & installed. This is the correct EMPI 86-2411D  - replacement inner boot  - about 1/2 the price of the Volvo boxed CKN boot (31256019, inner; 31256018 inner & outer kit). 

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Couldn't get the clutch hard line to seal in the air vent tube with out the shock load limiter in place, so I drill out the hub to match the normal flow ID. With the load limiter & original line seal, the line seals properly in the vent tube.

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Refilled the trans & started putting back all the odds & ends.  Modified the heat shield to allow install of the EBP line - 2nd shot's the charm ;)

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Hopefully wrap it up tomorrow: install injectors, water trap for EBP line, coolant hoses, IC hoses, battery tray, etc.

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Bunch of fiddly bits today - had to redo the IC/TB hose - with the deeper Porsche TB the hose is pushed into the AC pressure switch

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Larger 550cc  injectors for the K16 going in

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fitting the PITA upper IC piping & hose

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Turns out the later air vent pipe only needs the shuttle & rubber block to seal. With the extra ones from the old air vent pipe, the line blew out when I pumped the clutch.

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Blue piece is the shuttle that I drilled out (after taking this pic) to match normal flow orifice

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Removed the two extra seals, and it's all good. Got the Mrs. to help bleed it, and then put everything else back together - new rad hoses, overflow hoses, battery, air box, etc. I swapped out all the regular hose clamps on the DO88 kit for Oetiker clamps.

All back together & running. Now I have to get used to the heavier clutch again :) Exhaust blanket is making quite a stink also. Hopefully that will settle down soon.

 

 

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On 4/13/2017 at 7:29 AM, NEU said:

Was wondering if this was coming together before Carlisle.

Hello Neu- not sure I'll be bringing the C30. The plan was to have the body painted on the Fiat - and bring that :) not sure that will happen before Carlisle, so it may be the C30!

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Nice work (as always) Hussein! You made short work of the K16/SMF swap.

Can you explain more about what you ended up doing for the IC/TB hose?  Matt put the Porsche 70mm TB on his car and the do88 IC/TB hose hits the AC switch. It's a 1 piece silicone hose. He spent a long time fighting with that hose to get it aligned and secured in place but due to the rubbing it's not a permanent solution.

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9 hours ago, andyb5 said:

Nice work (as always) Hussein! You made short work of the K16/SMF swap.

Can you explain more about what you ended up doing for the IC/TB hose?  Matt put the Porsche 70mm TB on his car and the do88 IC/TB hose hits the AC switch. It's a 1 piece silicone hose. He spent a long time fighting with that hose to get it aligned and secured in place but due to the rubbing it's not a permanent solution.

I had to sleeve the Elevate hose with a section of another hose - you can see it near the top. I added that AFTER I found the rubbing through (visible at the elbow) - but I think it rides up from the motion of the engine. The reason mine is two-part is due to the larger Bell IC I/O - I bought a silicone step 90º to transition from the Elevate to the IC. I was going to leave it at that, until I found the damage to the hose above.

With the new hose, I added a section of addtional hose around the elbow secured with a industrial tie wrap, so the pressure switch rubs that instead of the hose. There is no way to avoid contact with the Porsche TB offset that I can figure out yet. Perhaps cutting back the top of the 45º so that the hose isn't pushed forward will work - I didn't have time to play with it further yesterday as I absolutely had to get the car back together & running. 

Pretty sure I will be spending more time on it - I lost the section of 2.75" IC piping & intended to use as the bridge, and had to use a section of 3", which adds to the problem by swelling the two silicone couplers in already tight areas. The lower one is now almost touching the lower rad hose. Can't figure out what I did with all my 2.75" IC piping from the early XR IC setup - I have plenty of 3" & larger section :( I'll have to buy a piece. The more I look at it, the more I'm sure cutting back the top 45º where it attaches to the TB will do the job - that may not work with the DO88 / Elevate hoses, unless they have enough 'stretch' - Mine I can adjust overall length to compensate as needed.

 

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Thanks for the explanation.   Hopefully Matt will chime in here but last we discussed it he was contemplating buying a new IC/TB setup from Sico Developments in the UK https://www.sico-developments.co.uk/collections/2009-2011-mk2-focus-rs/products/focus-rs-mk2-70mm-cold-side-boost-pipe?variant=27924274833.  It appears to be very similar to the piece you made.

The do88 hose is one piece of silicone from IC to TB, so it is kind of difficult to install.  However, the all silicone construction makes it easier to flex around things.  The multi-piece setup from Sico looks like it has a kink in the aluminum pipe that should clear the AC hose, and comes with a larger elbow for the bigger TB inlet.

 

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Sounds like that maybe the way to go. Here's a detail shot of the sleeve around the new pipe

Looking down 

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Looking forward from the motor side

 

 

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Water trap for EBP line to guage

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Found out that the system was overboosting significantly with the new setup. Shown here is 6th gear, progressive throttle.

Reverted to stock Pierburg TCV, no change.

Revised the IC-TB hose to 2.75" (made a dogleg pipe from mandrel bend pipe, with 3">2.75" 90º coupler off the IC and 2.75" I/O coupler to the TB)

Reinstalled the stock TB instead of the Porsche unit (porsche unit was fine with K04 & Elevate tune)

in place

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no more contact with rad shroud or AC pressure switch

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Boost is now rock steady at 21psi IBP, and part throttle surge has all but gone. I can live with this until I get a Hilton tune underway

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Forgot I reworked the inlet to snorkel pipe this week. Went through a couple versions before settling on using the stock snorkel cut back to remove the bottle neck 

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Made a baffled expansion tank for the X1/9

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drilled & tapped T/stat hosuing fittings for 3/8NPT vent (10 AN fittings) & 1/2NPT feed (12 AN fittings) 

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almost done

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AN fittings don't work here - hose runs are too short & so connection is too bulky and rigid - not enough give to allow for normal engine movement  - fitting came loose on the feed line after about 5 miles spirited driving. I stopped every couple miles to look it over, so no biggie, but they have to go. Back to my tried and true plumbing fittings (on the vent line) ;) 

gonna look like this: 

5/8" compression olive is sweated onto 1/2" pipe to replicate typical pipe fitting bulge/ridge.

B0E88B4B-F07D-4888-9006-2A0C9E92CBF2_zps

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Current news is that while the Elevate tune delivers in terms of nice power upgrade with the K16 hardware, drivability with the tune sucks ass. Cold start is a pita - car will stall / not start for a couple tries. Stumbles, hesitates, jerky throttle response until warm. Subsequent starts mostly OK, but some uneven behavior. On the road, holding a steady light throttle when crusing for example, gives a 'surge' that is really annoying. Progressive throttle results in boost which will suddenly drop out unless you continue to add more throttle. Boost transitions can be jerky.

Overall, it really makes driving the car annoying. I would NEVER recommend Elevate afer this. He basically said it must be mechanical as software doesn't change. Not going down that road, it's akin to ARD's claims to ppl that the issues developed after using his tunes must be their hardware, not his tuning (talking about setups where the hardware is all known good, new parts, maintained no vac leaks, worn parts, etc., exacerbated by higher power levels).

Paid for a Hilton tune on Friday, so that process is now underway. Very annoyed that I threw money away on the Elevate tune. 

I'll be driving the X1/9 to Carlisle, it's all flat black for now, after Carlisle, I'll hopefully have time top strip it back, fix the final imperations/details & prime it properly in prep for top coat in Volvo Passion Red 612

 

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