@ Alesi: thanks for the advise. I dropped John an e-mail and I hope to get a reply from him soon.

@ Omran: thanks.. I will be pushing them a lot in the next few days. I have 21 days holiday as you know so I'll be their pain for the upcoming period

I'll use the standard turbo oreientation as a guid to rotate the compressor housing of the GT2871, it should be facing the floor.

Finally, the turbo (GT2871R) is in. I think they've done a good job, Here are some photos :

Turbo - 1

Turbo - 2

Turbo - 3

Turbo - 4

Now, they need to paint the engine bay before fitting the engine but their body workshop is busy at the moment and will take them a week to start with my car

Here are some bad news, Fiat agent told me that they will not fit the APEXi AVC-R boost controller because they think it is a complicated job! so I need to fit it outside when I take the car. In order to run the car for the first time, is it ok to fit the standard EBV or shall I fit a manual boost controller? I'm supposed to run with the standard ECU chip and base boost during the engine break-in period before I move to FC Peformance stage 5 chip from Flea

good, good, good project...

Good news Hani. Like you already know i like your project



That's what i plan to do with mine too

Running "slowly" with my actual own eprom and standard injectors during the time needed to break-in. Inch by inch i will increase the RPM and the boost until the boost applied requires bigger injectors. From that moment it will be time for BIG POWER

I think you can do like that. If we are wrong, just let us know guys how to do better.

@ Oracle, thanks mate

@ MiniPit, thanks mate, I'm waiting for your project as well

If this is the case, I'll be running the standard EBV. But here comes the question, the EBV has 3 hoses as per this diagram:



1 hose from the EBV to the turbo wastegate actuator
1 hose from the EBV to the turbo compressor housing
1 hose from the EBV to the SIP

Now, the 3" SIP that I have doesn't have any hole and the GT2871R doesn't have any hole in the compressor side (like the standard turbo) so I'll end up wit one hose connected to the wastegate actuator. Does this seem correct and will it be running on base boost like this? any thoughts mates?

I'm concerned because the people who are fitting the engine (Fiat agent) is not familiar with these tuning issues they only work by the book

Just join the compressor and wastegate pipes together and leave the ebv plugged in. You'll then just run off actuator pressure.

The Apexi is easy enough to install.

Thanks Flea. So if I do this, the boost will 14psi which is the actuator pressue

I know that the APEXi is easy to install, but these people are killing me I have to talk to their electrician again and convince him to install it for me

Yes. Between 12 and 14 psi (IIRC) depending on how it is adjusted

(You can change the hardness playing with the nut which is on the rod)

Thanks MiniPit




I'm still confused a little bit and I want to confirm this with Fiat garage tomorow as I will be travelling for 2 weeks and expect them to fit and run the engine during my leave

Now and looking at below skectch, I presume the connections will be as follows:

- The EBV will be connected to the ECU only (not shown below)
- Hoses 3 and 4 will be connected to each other
- Hose 7 will not be used



Can anyone confirm above connections in order to run with base boost?




Also, this means that I should have a bose in the compressor housing of the GT2871R. Unfortunately, it doesn't have. I found this interesting QuickTap in ATP which will save me the drilling of the compressor housing. I think I should get it, it will look like this:

You're right Hani

If you disconnect hose 7 from the EBV don't forget to block it with a little plug

About the Quicktap, that's what i've bought for my GT30. I don't have the connection on the compressor housing too. I was affraid by air leak with this system but ATP told me lot of people run this Quicktap and there is no problem with it.

I run a quick-tap with my 28rs and its fine

Ben

@ MiniPit, thanks for confirming the EBV connections and your input on the quicktap

@ Benny, thanks for your input on the quicktap

I'm travelling tomorrow for 2 weeks vacation. More updates when I come back

I run with the same turbo (GT2871R), but my turbine housing is a T3 A/R .63, externally wastegated.

Congrats for you project, but as someone who suffered a LOT of issues and bugs during the process of 'make things happen', i'd like to leave a conseil to you:

I think your oil return hose - like I see on the pics above, is obstructed. You can solve this by moving and untighten the CHRA bolts, positioning the return hose at a straight and smooth line to the crankcase plug.

My wishes of success!

Weiler

Thanks Weiler for your wishes and the note on the oil return pipe, I'll see what we can do about it

Got back from vacation and visited Fiat workshop.

They have fitted the engine and the fuel pump but without the wiring mod.

Now, they are working on fitting the other parts: radiator, intercooler, exhaust system, etc.

Here are some photos of the engine bay:

Engine - 1

Engine - 2

Engine - 3

Not a neat job, I know. We have a dusty weather and it is useless to clean everything now as it will get dusty agin once it is on the roads. However, I'll give a polish job for the engine once all works are finished.

More updates later this week

Update:

intercooler, radiator, dump valve, exhaust are all fitted to the car and it is almost ready to run.

Some photos:

ProAlloy FMIC & Radiator

GT2871R Turbo & Sheild

Turbo & H&S Downpipe

HKS Dump Valve

Downpipe and SS Decat

BlueFlame Catback

BlueFlame Back Box

One minor issue, I found that the SIP hoses are a bit loose (I ordered the 80mm hoses rathar than the 76mm ones for a 3" SIP). I tried to source them locally but couldn't. I will ask the workshope to fit them temporary and I'll buy new ones online to be fitted later on.

When I left the workshop, they were fitting the suspension parts (OEM shocks and Eibach springs, front and rear). OEM Brake discs and pads to follow.

The workshop people didn't know what to do with the hose coming from the crankcase ventilation system separator (as my SIP doesn't have any ho;e), so I bought this breather for them to fit.

After that, thay will fit the PIU front bumper and the LE side skirts and give the car a full paint in black

Getting closer and closer

Looking good as always

A few things i spotted, have you got the original heat shield
which you need to fit over the oil return from the turbo

and you need to run a turbo support bracket.

Ben

congratulations hani,,,its about to be true

dont worry about the wiring mod, we will do it anyway,,,it would be easy though..

@ Benny, Thank mate The oil return pipe heat sheild and the turbo support bracket are availble and will be fitted.

@ Omran, thanks for the usual support from you mate

I had a small problem with the routing of the ProAlloy FMIC piping and hoses. I ended up using one of the OEM hoses and it was connected to the plastic pipe (which connects to the throttle body). Omran came along and helped with the routing.. thanks Omran

The workshop has almost completed the mechanical works and moving to electrical works and connections.

Engine startup shall be very soon

Electrical works are done on today. Fianl works on AC, fans, hoses, wires,.... etc.

Engine Bay - 1

Engine Bay - 2

They fitted the quicktap on the turbo compressor outlet hose and connected it to the the wastegate actuator

QuickTap - 1

QuickTap - 2

For the brake system (front and rear), they have skimed the brake discs, fitted new pads and painted the calipers

Front Brake - 1

Front Brake - 2

Rear Brake

Mineral (non-synthetic) oil, gearbox oil, cooling water, brake fluid, power steering fluid are all filled in the car.

Finally, they are starting the car for the 1st time on tomorrow. I'll be there when they start it and can't wait for it

good luck hani, hope you all the best,,,, let me know the results mate...

hope its gone well Hani!

good luck!

Thanks Omran and Marco20valveT

It's been a nice day with a smile on my face

They started the engine.. here is a short video I took.

No stange sounds or strange lights on the dashboard. You can notice the Coupé paranoia; I went to the cabin to check the oil pressure and I found it on 3 bar

However, 4 of my injectors didn't work and they used the injectors of another Coupé which was in the workshop. Above start was with the other car injectors, this is why they are the holding the fuel rail during the start (they didn't fully fix it).

Anyway, my injectors are OEM ones but Barbz cleaned them before fitting them to the engine. I'm not sure how they failed to work. Fortunately, they have 4 new injectors in stock and they will manage to fit them. I'll use the OEM injectors, 3.8bar FPR and the Walbro 255lph fuel pump (with wiring mod) for fuelling during the break-in period. After that, I'll fit the big MAF, 440cc injectors and stage 5 chip from Flea.

On today, I've choosen the color of the paint for both body (Code 601 – Nero met - Black metallic which came on the 98-99 LE edition) and wheels (dark grey)

The worst thing on today was when they told me about the cost figures upto date , my wallet will suffer for the next couple of months

Anyway.. I'm happy on today. It's a matter of couple of weeks and the Coupé is on the roads again

Nice work!

As i said a few posts above, i've fitted this turbo (GT2871R) on my FIAT Marea 20VT.

I'm using 5 Siemens 55lb/h injectors to feed 432whp with ethanol. I think the 440cc/min (~42 lb/h) injectors you intend to use are perfect for the application running with gasoline.

About the FMIC i see on the pictures, i think it is a little big to this turbo, specially if you use low boost (less than 15psi). An oversized intercooler will increase the turbo lag, wich sucks on daily-driving conditions.

You should imagine how much air the turbo will produce to fill this IC. I think its a lot of air. This is how i guess you will need to run with higher boost 20-25psi or more!!!

To have an idea, my FMIC has 55x30x5cm and guys here in Brazil who runs with GT3076R uses 65x40x7cm for 600whp and up! My car has full boost on 4500rpm....

Off course, this is just my opinion!

Anyway, good luck!

Thanks for your comments and wishes Weiler

Regarding the fuelling, as you mentioned I think the 440cc injectors, walbro 255lph fuel pump and a 3.8bar FPR will be enough for my car, Flea confirmed the same as well.

As for the FMIC, I feel the same (big FMIC) everytime I look at this photo



Actually, this FMIC is the famous ProAlloy FMIC and I got it back in 2005 from the 1st group buy organized by Phil (Highwayman).

Believe me in this country, I need a proper cooling and I based my selection on the results on Phil's car and the interest generated by many Coupé users in here. After that, it has shown very good results and I recall there were 4 or 5 group buys after the first one.

I'm quoting the specs of this FMIC from an earlier post by Phil:



I know it is a little big + its routing is not the best and might cause some lag, but will see.

Boost wise, I hope I can see full boost by 3,800-4,200RPM and don't worry, it'll not be less than 25psi (1.7 bar)

Why do you use mineral (non-synthetic) oil?

Only during the break-in period Freddan.

AFAIK, for a re-built engine and during break-in period, it is preferred to use mineral oil for proper seating of piston rings. Mineral oil has low lubrication and hence high friction which helps the rings seating.

Quote from Wikipedia on one of the disadvantages of synthetic oils:



Anyway, after the break-in period (which will be around 1,500km), I'll use a fully synthetic oil, most probably Mobil 1 15W-50.

Hi,

You have the HKS dump valve, but you do not have MAP sensor like 16VT has. I had HKS (chinese copy) without recirculation. I recommed to modify it to bypass and route the measured air back just after Air Flow Meter.

Then you car won't turn to rich and hesitate so much after gear changes.
You can buy this small add in pipe to you HKS from ebay for example.
Do not worry, you still get the nice sound !
http://i723.photobucket.com/albums/ww234/ismo67/Directinductionpipe2.jpg

http://i723.photobucket.com/albums/ww234/ismo67/BlowofftoBypassSSQV2.jpg

Recirculation Fitting to SSQV:

http://www.frsport.com/HKS-71002-XA001-Recirculation-Fitting-for-SSQV-Blow-off-Valve_p_12931.html

Thanks Ismo,

Actually, the HKS DV has the bose for the recirculation (see red circle)



I think they have connected it by now. Need to update photos everyday now