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  1. #21
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    From the bodged job with 2.5" pipe sleeved over 2.25".

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    To a proper job with 2.5" all the way.

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    Also had a dyno run, but it transpires that the job is not jobbed yet?

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    With the exhaust and intercooler upgrades, it should have more power than this.
    (Link below to a graph of expected power without exhaust or intercooler upgrades)

    https://www.bsr.se/images/power-char...-220339830.png

    I have contacted BSR and asked what may be the cause. Response below.

    "Most common problem when having low power on this model is

    - defective fuel injectors (most likely).
    - leaking EGR
    - defective boost regulating system."


    Given multiple options, I'll begin with the cheapest and easiest.

    I haven't yet fitted a new fuel filter, so will try that first and give the boost regulator a good clean, because that job is free.
    Last edited by David P; Saturday 9th January 2021 at 19:09.

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    kmb (Saturday 9th January 2021)

  3. #22
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    Back in an AWD....Oh the grip!
    Dangerous Dave's Avatar
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    Much nicer looking exhaust job

    Yes it's always a nightmare when the power is down on what it should be, but then it is exposing other issues which would have been causing running problems anyway so all will be well once those are sorted

    Keep the updates coming!
    1996 Olive Green 850 AWD - Follow the Project - Forged rods, 19T, big blue injectors, 960 TB, 3.25" MAF, Ostrich, 608 binary, arduino data display, active exhaust control with Focus RS tips, 320mm front brake conversion.
    1996 Nautic Blue 850 AWD - Failed its MOT, now it's a donor for the green thing.
    2004 Sapphire Black S60 D5 - The new daily hack.

  4. #23
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    Plenty of mid-range torque there!

  5. #24
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    There's plenty of torque at it's peak, but it should be a much flatter curve.
    Whatever the cause, unfortunately it's not showing a fault code.
    I have put 'check swirl-flaps operation' onto my job list.

    However, my degenerating spine doesn't like Winter weather which combined with isolation and complication from Covid 19 shielding, progress will be at a geological pace.
    Last edited by David P; Saturday 9th January 2021 at 19:20.

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    kmb (Sunday 10th January 2021)

  7. #25
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    Tuesday next week is scheduled to have the Monkey Nic bodges corrected; heat damaged track-rods & ball-joint ends and the melted C/V boot replaced. Since he also fitted the new callipers, it's now showing an ABS fault for both rear brakes which will be investigated too?

    Whilst it's there, the fuel filter complete with a new body is being replaced, if this doesn't cure the missing power, I'll have the injectors refurbished?

  8. #26
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    The Monkey Nic's carnage has been repaired and I now have faith that a track-rod won't fail and at the same time a new fuel filter complete with new body has also been fitted.

    Because the roads haven't recovered from yesterdays snowfall, I haven't yet been for a blast to decide if the lost power has been found.

    I will let my bum dyno decide as soon as it is sensible to do so.
    Last edited by David P; Tuesday 26th January 2021 at 22:14.

  9. #27
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    I have been out for a trundle and my bum dyno reckons that the new fuel filter has found some or all of the missing power.

    Will book it in for another dyno run to confirm?
    Last edited by David P; Wednesday 27th January 2021 at 16:38.

  10. #28
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    Keep us posted on the results, glad you're making progress.

  11. #29
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    It has developed a squeaky auxiliary belt tensioner pulley, so I will have that changed along with the belt and fit a new crank pulley before it goes back onto the dyno.
    Last edited by David P; Thursday 28th January 2021 at 00:48.

  12. #30
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    The service items required have arrived and are scheduled to be fitted Thursday 11th February.

    Keeping my project moving and Covid secure, the local Garage is only 50 metres away, they collect & return my car and I pay their account with debit card using the phone.

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    Last edited by David P; Monday 1st February 2021 at 18:44.

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    kmb (Thursday 4th February 2021)

  14. #31
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    It turns out that the squeaky pulley was on the other tensioner, so another complete with belt is on it's way...

  15. #32
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    This time, it turns out that the Garage gave me the wrong part numbers for the components required.

    Hey Ho! Here we go again...

  16. #33
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    The squeaking Gremlin is now history. Hurrah!

    It now has a new tensioner & belt for the alternator, a new tensioner & belt for the air con, a new crank pulley and a set of new fasteners for the engine bottom cover, so I would hope there will follow many service free miles from that neck of the woods.

    With that annoyance out of the way it is ready to be reduced to numbers again, however, in the great scheme of things, it may be prudent to reserve that dyno day out until after I have had my second Covid 19 jab.

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    kmb (Tuesday 9th March 2021)

  18. #34
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    They're only numbers that I can't brag about in Pubs that are closed!

    The car's mechanical functions have now been renewed-upgraded and/or serviced into fine enough fettle to go out and 'play-safely' with these as yet unquantified horses, my cup is definitely more than half-full.

    On Wednesday, I gave these mythical-horses some mystical-carrots to chase along my favourite B Road.
    It was @ dusk, 8 degrees C, light rain, greasy patchy-surface, potholes various/many, loose-gravel patches and recent agricultural traffic soiling, which set the Michelin All Season Plus tyres a good challenge.
    Not 'ideal' conditions in which to play with 'ginger' throttle control and 'preemptive' ABS free braking.

    The car now has a lot more grunt, with at least as many mystical extra ft-lbs as there are bhp's, which in these conditions were more useful than the horses, not once @ WOT, even though, 1C Leptons mystically momentarily arrived.
    In these 'extreme' conditions it was not a 'happy car', skittish traction with handfuls of nothing understeer/various; being the car's mystical response to almost everything. Predictable-ish enough, but more of an un-nerving than an inspiring drive. Warmer, drier and better surfaced A Roads and this will be a happier car.
    Last edited by David P; Friday 12th March 2021 at 02:15.

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    kmb (Monday 15th March 2021)


 

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