Tightmopedman9 Posted August 11, 2014 Report Share Posted August 11, 2014 Also installed a Volvo ECU fan (8666595) while I was in there. Powered from the Cooling fan circuit, so it turns on with the cooling fan @ 83ºC engine temp That's awesome! I always wondered what the empty tube behind the ECU was for. Quote Link to comment Share on other sites More sharing options...
TIZIO AKA 1 HND MEC Posted August 11, 2014 Report Share Posted August 11, 2014 That's awesome! I always wondered what the empty tube behind the ECU was for. Volvo Engineering!!! H, your car is even Cooler Now!!! Quote Link to comment Share on other sites More sharing options...
ozzimark Posted August 13, 2014 Report Share Posted August 13, 2014 I'm horrible at math. Can anyone help me figure out what the % drop or change in alternator RPM would be going from a stock 56mm OD pulley, to a 70mm OD pulley? Basically 1/2" increase in diameter.Alternator speed will be reduced to 80% of the original speed. At 8krpm with the new pulley, the alt will be spinning the same speed as it was with the old pulley and the engine running at 6,400rpm. :) 2 Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted August 13, 2014 Author Report Share Posted August 13, 2014 Alternator speed will be reduced to 80% of the original speed. At 8krpm with the new pulley, the alt will be spinning the same speed as it was with the old pulley and the engine running at 6,400rpm. That's the number Piet came up with - which is perfect, since 6,4K is about where it dropped off below 13V Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted August 30, 2014 Author Report Share Posted August 30, 2014 Finally have the X1/9 back on the road, running LH2.2 from a 240. Next I'll build an EZK117 system for it. so I spent today working on the fuel delivery mods. Cut an accèss panel out on the left side Pulled the existing senders, cleaned up, hinged & painted the left access panel transferred the pump & level sensors to the ones I modded with 3/8 feed & return lines with quick release fittings Installed a new 10mm ID crossover pipe with 3/8 quick release fittings, above the gas tank & subframe, installed both senders with new seal rings. Access panel is sealed with butyl (dynamat strips). Wiring Tomorrow I have to install the modded fuel rail, make the stainless braided fuel feed from the AEM FPR to the rail, set the pressure to 3.5bar, and check the system for leaks. Then I'll cut out all the old lines. The adjustable FPR I'm currently using will go into the X1/9, so I can tweak that as well. Quote Link to comment Share on other sites More sharing options...
VolvoNor Posted August 30, 2014 Report Share Posted August 30, 2014 Nice clean work as always. Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted August 31, 2014 Author Report Share Posted August 31, 2014 Primed the surge tank to confirm my in tank pump wiring is correct. The DW300 pushed fuel to the AEM FPR up front in just a few cycles of the key. Once the surge tank was full, I hooked up the Bosch pumps & installed the modified rail with AN8 inlet. Finished making the braided flex hose once I had the precise hose routing. Fitting the Straight fitting (FRA-680108-BL) to the SS braided PTFE (Fragola 603008) hose was a real bitch - I don't recall having such a hard time with the elbow end. Problem is, the rail I made to replace the earlier version leaks . I re-welded an obvious piss-hole, only to find it sprung another leak. So, I have to adapt my earlier rail & add a AN-8 bung to the inlet - the reason I didn't do that in the first place is the interference with the T/stat housing & hose. The later rail has the inlet raised. (pic from the spring) Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted August 31, 2014 Author Report Share Posted August 31, 2014 Drilled & tapped the earlier rail for an AN-8 o 3/8NPT fitting. It's a little tight around the coolant hose, but not rubbing. Set the fuel pressure to 3.5bar (51psi) with vacuum disconnected. Left side access flap in place, butyl added from the outside of opening to seal the flap when closed ready for inner seal Removed fuel lines from the tank forward. Old lines over the tank were cut back, I'm not going to worry about extracting the remnants. Filter removed from top of subframe. Vacuum port for FPR on intake pipe capped, main vacuum rerouted to AEM FPR. All back together. Now I need a virgin cam gear cover . EDIT: Couple of things; I need to rubber >mount the surge tank , as although the 044 pumps are pretty quiet, I can still hear them with the tank hard mounted to the floor pan. Also ordered a Fuelab 85811-1 filter with integrated check valve (to replace the billet Summit filter I had installed)- it's rated for 2000HP/200GPH, so no flow restriction problems - I removed the stock Bosch pump check valves because I couldn't find an adaptor to go from them to the AN -8 line fittings, and they look like a flow restriction to me. 1 Quote Link to comment Share on other sites More sharing options...
dougy Posted August 31, 2014 Report Share Posted August 31, 2014 nice ! You'll find one, they're all over JY. Quote Link to comment Share on other sites More sharing options...
sjmcarz Posted September 2, 2014 Report Share Posted September 2, 2014 (edited) H, I may have a cam gear cover in the garage if you don't get to a JY. I'll check. Edit: I do have a RN gear cover, pm me if you would like it. Edited September 2, 2014 by sjmcarz Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted September 2, 2014 Author Report Share Posted September 2, 2014 H, I may have a cam gear cover in the garage if you don't get to a JY. I'll check. Edit: I do have a RN gear cover, pm me if you would like it. Thanks for the offer - I did find one cheap on eBay. There is no such thing as JY access around here, been that way since the late 80's - the EPA took care of that . Quote Link to comment Share on other sites More sharing options...
sjmcarz Posted September 2, 2014 Report Share Posted September 2, 2014 Thanks for the offer - I did find one cheap on eBay. There is no such thing as JY access around here, been that way since the late 80's - the EPA took care of that . Ok. Just your area for no junkyard access or all of NY state? Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted September 2, 2014 Author Report Share Posted September 2, 2014 Ok. Just your area for no junkyard access or all of NY state? Don't know about upstate. We are downstate, only 15 miles or so north of Manhattan. There are still a couple of auto recyclers in my county and others across the river, but nothing here or in neighboring New Jersey townships that allows public access anymore. They just recycle the scrap metal, no parts sales. Pretty much when the EPA came around & shut down many gas stations due to leaking tanks back in the 80's, they also went after all the JY's at the same time. I used to enjoy just walking through to look at the old cars you just don't see anymore. Quote Link to comment Share on other sites More sharing options...
Johann Posted September 2, 2014 Report Share Posted September 2, 2014 Wreck yards in my country had to change their way of dismantling and storing the wrecks, Non dismantled cars need to be stored on sealed concrete surface. Many company's bought special fluid removal and storage equipment. Only when the wreck is totally fluid free they are allowed to be stored on non paved surface. Quote Link to comment Share on other sites More sharing options...
lookforjoe Posted September 13, 2014 Author Report Share Posted September 13, 2014 EDIT: Couple of things; I need to rubber >mount the surge tank , as although the 044 pumps are pretty quiet, I can still hear them with the tank hard mounted to the floor pan. Also ordered a Fuelab 85811-1 filter with integrated check valve (to replace the billet Summit filter I had installed)- it's rated for 2000HP/200GPH, so no flow restriction problems - I removed the stock Bosch pump check valves because I couldn't find an adaptor to go from them to the AN -8 line fittings, and they look like a flow restriction to me. Been getting the X1/9 run in. Still waiting for the Fuellabs filter/check valve. I've been struggling with an ongoing issue that started in the late spring - it started as an intermittent 'stutter' in the part throttle-high load range, which from me is 3600-4600 range. After doing the fuel pump mods, it became a constant problem where I could not go over 14 psi boost no matter what, with terrible 'stutter'. I confirmed fuel pressure stability, waste gate operation, intake side integrity, etc. AFR's were not out of line, timing values also. After checking many things, I tried just putting in new Bosch DPP fine wire plugs, with a smaller gap of .026" - this immediately improved the drivability. That indicated to me that the problem is with one or more of the Coils, since I have always been able to run at least the stock plug gap of .030". I swapped all the coil packs out with the stock Bosch units in place of the Bosch MotorSport units, and my normal driving & boost is back with no stutter. I bought the MotorSport coils just under a year ago from ARD, and they said they will warranty any defective coils, so I just have to put them back one at a time until the stutter returns. Now that that issue is being resolved, I can raise the boost & get a dyno session booked this fall Warm Compression test: #1 190 #2 190 #3 185 #4 185 #5 185 Quote Link to comment Share on other sites More sharing options...
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