Ok, first the pics:

Pics

The car lives and drives fine, although I had some cooling issues with it, that I was sorting out throughout the week. First an old hose broke (was bound to, it was a matter of time, just had no idea it would last only 15km :/), then the fix broke the very next day (my fault: old plastic and excessive screw tightening don't mix up). Then I also fitted cooler stat (cheers Aaron for the hint and advice) and it seems to be under control. I also already managed to semi-seriously scratch the downpipe, damn speed bumps Right now I am running in the engine, which means no boost and very gentle driving in general, next weekend (hopefully) first oil change, oil cooler fitment, and then I can start pushing it more. So no power or boost indications at the moment

Swap wise, I am proud to say that a complete swap (from drivable to drivable) took no more than full 4 working days, but with forced interrupts caused by weather mostly, so in total the car was off the road for one week. Also I made the choice to put the new engine in all in one piece (engine + gearbox + manifolds incl turbo), which actually slowed down the process considerably, because it was very tight and squeezing it in and putting back on mounts took close to 4 hours with 3 persons.

Not sure what else to say, just ask.

did you change the internals then? pistons etc?

what management are you running on it?

and finally, what turbo is that? It looks like a T2 but im not sure....


Nice progress though, youve definitely spent a bit of money and time on it

Munkul said:

did you change the internals then? pistons etc?

what management are you running on it?

and finally, what turbo is that? It looks like a T2 but im not sure....


Nice progress though, youve definitely spent a bit of money and time on it

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Decompression is done with a plate + 2 metal head gaskets. Otherwise internals are factory, but all seals, rings, etc. have been renewed. The turbo is RHB4 from IHI. ECU is an IAW 8F heavily reprogrammed to deal with boost, 2.5 MAP sensor, and 250ccm injectors.

Time was actually reasonable, I was expecting to spend more (I actaully wasted a bit of it on things I never needed, or had to redo), money wise, I do not even want to know anymore. It better run good for next two years...

Have Fun Its like a big jigsaw lol

It'd be interesting if you could upload the eprom file, but I guess this is asking too much

syaochan said:

It'd be interesting if you could upload the eprom file, but I guess this is asking too much

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Actaully, it is asking for too much It might be for sale later, but a few things are still unclear to me how to go about it, and for sure it is not going to be cheap

It'll be interesting to see if your 2 HG solution holds up or not, as opposed to using a single HG and bonding the plate to the head like normal.

Nice to see something different with the ecu programming, did you do it yourself or get someone to do it for you?

Munkul said:

It'll be interesting to see if your 2 HG solution holds up or not, as opposed to using a single HG and bonding the plate to the head like normal.

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Well, it should, common practice in Poland. The only thing is the tightening procedure, a bit tricky and on the edge

Nice to see something different with the ecu programming, did you do it yourself or get someone to do it for you?

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Also common practice in Poland, but this one is done really properly. My car is a third one running on this program. Most work was done by me, but a bloke back in Poland helped a big deal by testing my ideas and intermediate result on his testing equipment and his car while my engine was still in the basement.

cool

so when you say metal HGs you mean MLS? (multi layer steel)

Guesing you compensated for the extra squish by torquing the bolts a little further?

And will you be rolling roading it once its ran in? I'm very interested in seeing what sort of power you will make

Munkul said:

cool

so when you say metal HGs you mean MLS? (multi layer steel)

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Yes, from Grande Punto 1.4 8V. Two layers each.

Guesing you compensated for the extra squish by torquing the bolts a little further?

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Yes, 30 Nm + 90 deg + 90 deg + 90 deg. Doing the last 90 feels like everything is about to snap into pieces. But it didn't, it was a traumatic experience though.

And will you be rolling roading it once its ran in? I'm very interested in seeing what sort of power you will make

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Perhaps. I actually have enough equipment mounted into the car (AFR module additionally monitoring EGT, RPM, Boost, TPS, and knock too, although this last one I am not sure whether it will work at all) and enough software on my PC to do most of the tuning myself. Will see what the result will be and then deciding on the dyno.

OK, long time no report. It was dyno time today, and this is the result :

woj said:

Yes, 30 Nm + 90 deg + 90 deg + 90 deg. Doing the last 90 feels like everything is about to snap into pieces. But it didn't, it was a traumatic experience though.

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Hehe, I did the same. 30, 90, 90 wait a few minutes and did the last 90 degrees and hoped that the bolds didn't snap off.

Dyno plot looks oké.
Torque drops quite hard after 4000rpm with this engine. 8 valves engine and little valves.
But 120HP isn't bad. Is this with correction of your drive-train? And what boost?

Greets Dennis

Yes, this is all corrected. The dyno showed 103PS at the wheels (axels actually, the dyno is the fancy type that hooks up straight to your hubs, you can see than on the pictures linked above somewhere). The boost level is 0.8 bar, factory for a fresh RHB4 turbo from Astra (I had to use a fresh one, I abused one stud on yours so much during trial fittings, that it became unusable, sorry for the Dennis ). The torque drop is due to the small turbo, also the boost drops slightly from 4000RPM onwards to 0.75bar. But at least it drives nicely at the bottom.

funny to see that graph... the drop you can see it exactly what i would feel with the arsta turbo before i hybrid mine (mine was a garrett tho but most likely the same size)

it was a strange/nasty/disappointing feeling because the car will acceleration like a mad one and the drop off was like someone dropped anchor (it just felt that way... the car was still accelerating very quickly... just felt disappointing haha)

Had some fun with camera, video editing, and youtube uploading for the first time:

Did some minor things today. First I installed a bleed valve on the WG to play with boost levels at some point. You have to be a bloody surgeon to work on the front of the engine with a turbo in a Cinq, arms scratched up to my elbows :bang: Then, I inherited a fallen off cat heat shield off a Toyota Yaris and adapted it to what can be seen below. Finally I tried swapping 900 bob with a Palio bob. Two results: I cannot drive with a Palio bob in my car, it touches the hood and the whole car vibrates (but the hood closes), really sucks , and I did not see any real difference in power between the two. What I also noticed today, that I cannot boost the engine past 0.75 bar, although it was possible to boost it up to 0.8. Can this differ depending on the current atmospheric pressure? It's kind of on a lower side today...

What you can also see on pictures is the brand new 60 degree silicone elbow from Samco. Something I have been longing for for quite a while, somebody finally decided it might be a good idea to make one

What brand and type turbo do you run?

MKoers said:

What brand and type turbo do you run?

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RHB4 from IHI. Usually mounted on Astra's F 1.7D. Piece of crap according to what I am told. Meaning, people tell me I would be getting much more power with the same boost level from other turbos. Apparently this turbo is a really old design. But, it fits well

Hi! I like your car and project.

Where did you buyed the decompression plate and what are their prices?

What throttle body assembly are you using? Standard Punto 75? The Cinquecento 900 bob fits directly on it?

Do you run an intercooler? How's the tubes for it? Have any photo of the front of the car without the bumper?