Steve's Sport Evo Project

[stevesingo]

WIRING LOOM FINISHED (almost)

Aside from a terminal on the alternator output the wiring loom is finished. If there was ever a case of measure twice cut once, this was it. But it was immensely satisfying connecting the sensors up and watching the error warning go out one by on until I was left with just one, the ref sync fail. That won't go out until the engine is started.






Lambda sensor plug mounted to a bracket fixed to the bell housing.

Need to make a bracket for the cam sensor plug.

Just the crank sensor to position and mount.


Because I no longer have a need for the Diagnostic connector, I removed the bracket from the loom cover and used the space for the brake fluid reservoir.



I have been playing with the ECU software and gauging the position for the crank sensor.

The software is quite clever in that it allows you to capture the signals by way of an oscilloscope.





All seems well. All I need to do is knock up a drawing for a bracket to mount the sensor.

[xworks]

Great work, very helpful pictures.

[stevesingo]

I have been working on the oil cooler in the last week.

I bought a M635CSi cooler from BMW Pt No 17 11 1 176 458. Although the cooler is similar, albeit deeper and taller, the mounting brackets are wrong for the e30 chassis.

I cut off the old brackets and made some new ones from aluminium sheet so I can use the original mount points and close to original hose routing. Got my brother to TIG weld them on and pressure tested the cooler to 8bar with nitrogen. At work!

I have also decided to use JIC/AN fittings on the hoses as the new cooler does not allow the use of the stock pipes/hoses due to the size difference. So, custom hoses were required, but findinf metric fittings in the UK was a mission impossible, so Jack @ Elephant Motorsports supplied me a AN kit for the hoses, with adapters.










Test fit tomorrow.

Steve

[diegom6]

Steve, why did you get that oil radiator? Because is a tad bigger and cheaper? Nice welds!

[stevesingo]

It is slightly bigger, the same as the early Gp A cars used.

Some pics I dug up...





Steve

[stevesingo]

Test fitted and all looks OK. don't know how it will interact with the duct in the bumper though?







Just need to finish the hoses and give it a lick of paint.

Coming Soon, More X pipe work and Prop shaft.

[UweM3]

Steve, I am using that cooler as well. The bumper will fit if you remove the plastic duct. But I am sure it can be trimmed back to give at least a little bit of assistance with the airflow.
Beware, the duct is NOT available as a single part. I had one left over from a broken bumper and gave it to TR-spider who reported a 15 deg drop in oil temperature after fitting the duct!
PS I am 99% sure I found a place with metric fittings in the UK, but you are correct almost mission impossible!

[TR-Spider]

I had one left over from a broken bumper and gave it to TR-spider who reported a 15 deg drop in oil temperature after fitting the duct!

I am still grateful for that, Uwe!
The duct piece and the top cover are essential to guide the airflow into the oilcooler and prevent the air from taking the easy way and bypassing the oilcooler. Thus the cooling air flow is increased and the oil temperature lowered. The drop of 15° simply shows how effective that little piece of trim is.
I also thought about fitting the 635 oilcooler recently (witout rush).
What I will try is to mount it slightly tilted back on the top, which will both increase the area for the exit flow and make the retrim of the duct piece easier. The exit area is already quite tight, as the cooler is mounted relatively closed to the rear wall. Maybe it will need a redesigned duct piece.
I tried to scetch what I mean:


Thomas

[stevesingo]

My cooler is tilted back for that reason Thomas. I am reluctant to trim my duct until I find a replacement. I'll keep looking on ebay for a bumper or duct.

Steve

[diegom6]

Nice! What's exactly the air duct thign you guys mentiond, I don't have my car next to me so I'm not sure or can't remmber from such piece, any real picture of it installed? Thanks

[RDCD12]

I don't understand how you can ever drive the car on the road again after this!
Every stone chip would drive me mad! As much as I would like to build something up from the ground like you, as much I dislike the idea.
I think what has changed my mind was my time racing bikes. Spend all winter preparing the bike, only the finest on materials. Attention to detail beyond believe.
And then throw it into the gravel trap at the first race meeting...... [peace]

As I'm going through this thread, the exact thought is running through my mind....

Sell them on ebay

Thanks

Steve

[aropro100]

(I'm still looking, but Bosch EV14 0280158117. These are high impedance, have a split spray pattern and flow 500cc/m, but have very linear response down to very low pulse width so will be fine for idle. People are using 725 and 1000cc/min versions of these on 2.0lt Mitsubishi Evos with no idle issues.)


I am using m marelli iwp 069 491cc injector at 3bar .... no idle issues
my car was also tune on m800 and tansfer the data to my m4 and its running great... one thing my tuner did is he did use the fuel individual cyl trim and i felt it has make a difference. maybe you can try it when you get your car tune.

[stevesingo]

My second attempt at positioning the crank sensor didn't go too well.

Upon cranking I had a good signal from the sensor, until the engine came to an abrupt and sickening sounding stop! My first thoughts were cam timing, but it couldn't be as I had cranked it previously without issue.

Then I noticed that one of the ignition coils was sat in the spark plug tube. Inside the coil is a 30x6mm stainless adapter. With a sense of dread I removed the coil to find no adapter.:eek:

I turned the engine back, with some dificulty and went drinking. That was on Thursday. Tonight I removed the head!



As you can see there is a dent in the piston!





and a dent in the head



You can also see where the piston has rocked when it came in to contact with the adapter and the opposite side has kissed the head.



You can see this on the piston.

At least one valve is bent, as the clearance was larger than it was on assembly, but I'll check properly tomorrow.

I think the head will be OK. The dent doesn't look too bad, and doesn't run in to the seat and the witness mark on the opposite side can't be felt

Obviously the piston is kaput!

BUT, So is the block...



and probably the wrist pin and may be the rod:eek:

So yes, fucking hell!

I will pull the engine tomorrow and see what else is wrong!

What is the cost of an Evo3 block these days?

[t13vom]

Sorry man... so close...

[diegom6]

God lord! That must SUCK forever man. Sorry to see it go to hell that way.

Pardon my ignorance but what exactly you mean with an "adaptor" or any pics of that thing?

Sorry to see this tragedy :(