Fiftyone's Bitsa Build

[FiftyOne]

Anyone know what the smaller vac port in the manifold is? I can't figure that one out yet

[Wilko16]

Only a guess...

PCV maybe ?

[FiftyOne]

Nope. That's the bigger one. Thinking a vac line to the AC? Might plumb a tee in at the back and run it off the original bov line. Need to tap in for a bov line too. Was thinking about swapping the line to the brake booster over with the crank. The hoses fit better, however I think the brake line would be far too close to the crank vent = oil in the booster. If I can get another vac line the same as the front crank one (has a dog leg in it) I'll keep it at the back

[Wilko16]

What size is the barb? Also I thought the BOV and the fuel reg share the same line

And doesn't the front crank breather line join into the air intake pipe ?

What about fuel tank Vapor line ?

Also It is impossible to get oil in the brake booster... The engine is creating the vacuum, air is being sucked out of the booster, not going into it

Edited 07/04/15 08:55 AM by Wilko16

[FiftyOne]

PCV, crank, crank vent, blowby valve = all the same thing. Do appreciate the responses on that but I figured it out. Big one is the pcv, the little one is the ac hose.

I've been a little absent minded thinking about a heap of other things going on in life distracting me right now and unfortunately life is a bad habit I'm not ready to give up right now. I heard something once about a book called the zen art of motor mechanics. The pretence is about how those sh*tty hard jobs are actually an escape when they require all of your attention & focus. This build is a bit of a mental thing right now. Time for other sh*t and all the unexpected things is taking my eye off the ball a bit. But when I'm in the shed, the fires stoked, radios on and I'm quietly sipping a tastey beverage thinking about the problem I'm facing, I really enjoy it. Sounds silly but it's a bit daunting knowing there's this big scary thing in the shed that's looking to cause me grief at every turn but when I get started I make progress. I'm also starting to round out things now so I can finally see how it will all work which is ace. And it's an hour or two a day or every other day for now

Ok so things still to do;

Sort out & re plumb the vac lines, booster & pcv

Get more thread lock & bolt down the manifold

Mount & plumb the intercooler

Fit the pressure transducer

Chop the airbox to fit, bend the Ac line to clear everything (and if not disable it over winter til I can custom something up)

Mounting tabs to hold small things out of the way as well as get some pipework bent up to suit

Fix the rad

Reassemble & start (hoping to restart next Thursday for a brief time to see if the tune will work)

So on to the latest of the night - Got the right angle drill kit and event that was borderline close from not fitting in to position too

Learning the hard way that I've done this ass backwards as well. The injector rail is now in the way preventing me from using the expensive and hard to find 3/8th wobble attachment from doing up the manifold nuts. Also, pretty much forget torque settings on a nizzy plenum as you can't really get a tool in to get at them, so the FT system it is - stands for FFFFFFAIRLY!! Tight. It would be easier doing this BEFORE the injectors are reinstalled. On a completely unrelated note, trying to do injectors first is what led me in to this mess! The central nuts are the most difficult as they are more inboard and under the body of the thing. Everything else I will do up when I've got more threadloc. The stuff from factory is a right pain as it's everywhere in the threads you don't want it to be. As we do, we'll sneak a tool on it & get them all done up. I'll come back after a few heat cycles & double check them too. In my youthful rush brought a new gasket for it and modified it which has now effectively f*cked it so the original will go back on. It'll do

The tune has been uploaded and is ready to start. I've got some generic etc codes (p1000) which Re common for when things are disconnected I believe so we'll give it a kick in the guts soon and see how many injectors spray fuel external to the manifold or that throw codes etc. Flashing the ecu took longer than I though it would too. Noticed the ecu makes a high pitched squeal when it's working too

And the dark art for the night, the FG arrangement. So again a major call for a FG rocker cover of someone knows someone with a spare, but I can mod something to work. The below is a pic in the headlight area to see bonnet clearance.

Hard to see but the pipe opening is high as the coil cover is also high. I could get around it by chopping the foil cover but I'm super not keep to do that right now. And I think the rubber could maybe be put to a heat gun to warp and make work. I don't think this is the way to do it though as under bonnet temps are high in any car and nothing will ensure it will hold that shape, so thinking about a few options there. Worst case is I use that pipe as a template to have a custom piece made up and crashed to suit. Or maybe the bonnet lining will start to get a bit grazed by touching. Anyway we'll see what tomorrow brings but for now I'm very pleased with how it sits. I spied a few other photos of El setups that look like that could give a good inspiration to help get around the problems I'm facing too

The other issue is the tps. I didn't think these needed a tps as they've got a wired throttle but apparently they do. The top of the tps will rub in to the bonnet insulation too so I need to think about the orientation of the tb. Again that's a problem for not now.

Height issues at the moment to be solved;

Assorted cooler pipe to help with bends etc for now;

[FiftyOne]

Actually wilko you are correct. I didn't think of that. But I'll be keeping them as close to the original locations as possible. Last thing I want is the brakes to go on me for any reason 0_o

Also need to figure out how to get a vac line a little closer to the tb for the bov too.

Trying to upload a panorama shot of the engine bay but the phone isn't playing nice so that's the teaser for some other time right now

[FiftyOne]

[k31th]

well, that's definitely a different way to go about an engine bay! Kudo's to you for being different.

[FiftyOne]

Word to the wise wih a nizpro plenum install - manifold first, then fuel rail, then vac fittings. This is a right PITA now getting to bolts in a certain order. The whole job would be super easy if you are taking the full manifold off anyway (or if it wasn't in the car to start with) so that fantastic job getting things torqued and cross threaded has taken me a bit longer that I expected. And the saga continues!

Anyway, need to get a slightly longer booster line still, and figure out how to split the lines off for the bov.

Also took the pressure transducer out of the old cooler and I'm still weighing up whether I can just tap the end tank and screw it in without need for welding in a bung. So that's all today folks

[FiftyOne]

Again not much happening tonight but the big news is.... Engine starts! And f me wow. Other news is my whip that's been back on the rd less than 24 hours developed not 1 but 2 coolant leaks! Fml!!!!!!

Anyway, will be walking about buying parts for a while longer til that's sorted. Started to mount up the cooler tonight which took far longer than I expected as I don't know how it's all meant to bolt up. After a few hours of cocking about its mostly in. Boost sensor is in and the line is plumbed for that. One last bolt on the back of the manifold that needs to be torqued up right but I think we're apples!

The idle quality is unreal. First start it was like it was missing on a cylinder, hmmm. Thought it could be a bunch of things & sure enough that things you find, I'd removed a injector plug to get to a bolt. Back on and and it starts so dam well and idles so nice.

I'd also like to give people my experience with a few things.

First off to weaponX coils- so many people saying they don't help or improve the way the engine runs, stocks better bla bla. For those that have done the swap & aren't impressed, I'd have to ask whether they've had the tune altered to make them work. The spark dwell tables need to be altered to actually make them work correctly. Without the tune, yeah, you would waste your money

Second a shout out to both KPM & Herrod that respectively gave me the tune as I needed and gave super prompt service to help unbrick my flash unit. Customer service was top notch.

So basically I primed everything up and hit the go button and it started. Idle was high as I think the battery was low but I'll too that up before the first test drive. This leaves me some induction pipe work, vac lines and reassembly to be done for now along with the dam radiator that won't stop pissing on the floor

Got the boost transducer tapped in to the need cooler too. And it's a good thing the bumper has come off as the worm drive of he hose clamp under the battery was rubbing on the loom and had punctured the conduit.

Main goal for now will be to get the whip patched & source a new part for that, and get some pipe work on so I can just drive it around the block for a quick shakedown. The airbox will come later as even though it might suck a bit of hot air, it'll run fine and cause less issues without it.

Not sure how much I'll be working on this over the next week or so as I'm so over booked with other stuff it's not funny. Massive deadline to hit with a charity group I'm helping so here's hoping