thanks James, :although I think you have just cost me a little more cash

be interested to see how you get on

 

Will keep the thread updated so you find out

 

Alright guys, been a while since I updated this, and as i've got less then a week to get the car ready for a remap, i needed to pull my finger out and get to work on the car...

So last weekend, i put the new turbo on, and today, i managed to get the inlet taken off, to get the old fuel rails and injectors out, and convert to top feed injectors (Pink 550cc), with new parallel fuel rails (CDF Racing).

Still need to pipe them all together, and install the fuel pressure regulator.... But here's a few pictures from what i have done today

 

Looking good

I was going to ask you about the loom connectors for the injectors, I've got Carl Davey kit top feed conversion kit and some 850 PE injectors now...what are you plans James?

 

The connectors look like they are exactly the same (didnt check if they actually plug in though) will check tomorrow before i shoot along to Pirtek to see if they can make me up some braided lines

 

coolio...good luck

 

Well went to Pirtek this morning and got a few bits to let me finish plumbing the fuel rails in... cost me an arm and a leg, but I needed them so I could get the car finished for its remap on Friday.....

So here's the fuel rails all plumbed up, ready to be fitted back ontop of the engine


Putting everything back together, i noticed the connectors for the injectors are slightly different, so I took the Dremel out, and smoothed off the little notches on the injectors off, and the connectors are a perfect fit now (slide straight on and click into place)


Fitting the other bits back together, i now noticed the fuel rails foul power steering pipes, which means they cannot be connected back into the power steering pump, but I can see a way these can be modified (well an extension piece made up to allow it to sit further back) - although I was thinking about doing away with the power steering anyway, and just plumbing both pipes together, as I've seen/read someone else do on their impreza

Anyway, got most of the other bits back on, plumbed in the FPR, and thought i should give it a test.... turn the key and i heard a noise if someone had turned the hose pipe on... took a look and saw petrol pissing out the top of the injectors


Soo I dont know what to do now.... Supposed to be getting it remapped on Friday, but with injectors like that, i doubt very much it will be sorted in time for that

I dont know what to do to try and get the fuel rails sealing properly.... maybe new rubbers?

 

Personally i would cancel the remap and focus on the car dont rush to take the car to be mapped take your time mate

 

The car is on track on the 8th and 9th and this was the last time it'll get time to get remapped

Worst case senario, put old rails back on, source some 440cc side feeds and map it on that

 

Sorry to hear about the bad luck Jamz,if you need some 440's I have some you could have for £50 delivered mate

 

i think you need to speak to Chris...thats not a small leak

 

I hope that's the problem. Any idea where I can get a set from. Just asked Alyn at ASP but it's not something he stocks. Part numbers?

Need to get this sorted like yesterday.

 

Nice little change there on the post

Aye ive sent Chris a PM, so will see what he suggests... but I dont reckon it will be sorted this week

 

Im gutted for you mate hope you get it sorted before the tracks gud luck

 

lol sorry James, i assumed i knew what the leak would look like as I've suffered from a nicked o ring...but after checking your vids your leak is waaaaaaay bigger than any o rings leak I've ever seen before

Hope Chris can sort you out

 

Im hoping the o-rings are at fault here... took two injectors out of the car, and the rings are quite loose (dont think they are supposed to be this loose).... They have been sat in the garage for a while, so maybe they have weathered a bit in the garage. The other one seems a bit loose and has a couple of kinks taken out of the ring its self...

 

James, please give me a call I think I can see the problem here

 

Cheers Chris, hope this solves everything

 

what was the problem mate?

 

The problem was the injectors were going too far into the fuel rail when tightened up, so a little spacer was made to stop this.

Suppose I should update this as its now been mapped by Duncan, and on track again, but yet more issues

Had a few issues when taking it down to dunacans, was my fault for fitting the MAP sensor wrongly (doh), but Duncan managed to sort that for me.

Anyway, on the rollers, Duncan did his magic, managed to get 320bhp out of her, but had a huge misfire with anything over 1bar boost, so suggested I did the newage coilpack upgrade, which i did, and made a guide here:
http://www.jamessimpson.co.uk/classi...ack-conversion

Then it was soon time for this years RS Owners Club Day @ Croft Circuit... First session went alright, then I let my brother drive, and ended up putting it in the gravel pit - Which in turn popped the coolant hose off the bottom of the turbo, dumping all the coolant, and the start of more issues (over heating - air lock, and cracking the radiator)

So I managed to source a new radiator, which solved one problem, and managed to remove the air lock by filling the coolant back up through the turbo outlet, then I blew the gasket on the up/pipe where it connects to the turbo (making a strange whine sound)

By this point, I was tired and gave up, and sold my track day for the next day.

Here's some pictures from when it was on track




So things to fix now are the turbo gasket, find the rest of the manual windows and fit them... then im going to strip the dash down again and remove the redundant wiring, as there is a lot now.

Thinking about taking everything out again, and re-spraying the inside white.