Project Y's turbo conversion

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

Most of you know project Y.

For those that don't its a C type ph1 3 door carbed 19 in red with spanking bodywork.

Its being converted to a turbocharged engine.

I have already purchased a lot of stuff for this job.

So far, boost hoses, GTT inlet and exhaust manifolds, GTT carb, GTT water hoses, GTT downpipe and so on.

Today I cleaned up the manifolds and stripped the carb.

Inlet manifold as it came, sticky and oily

[img:567:378:0901d49371]http://www.renault-turbo.com/chris/GTT%20inlet%20man%2001.jpg[/img:0901d49371]

[img:567:378:0901d49371]http://www.renault-turbo.com/chris/GTT%20inlet%20man%2002.jpg[/img:0901d49371]

After a bit of magic

[img:567:378:0901d49371]http://www.renault-turbo.com/chris/GTT%20inlet%20man%2003.jpg[/img:0901d49371]

[img:567:378:0901d49371]http://www.renault-turbo.com/chris/GTT%20inlet%20man%2004.jpg[/img:0901d49371]

[img:567:378:0901d49371]http://www.renault-turbo.com/chris/GTT%20inlet%20man%2005.jpg[/img:0901d49371]

Looks great now eh! I am contemplating removing the external casting flash and also trying to smooth the awful bored hole for the carb.

exhaust manifold

[img:567:378:0901d49371]http://www.renault-turbo.com/chris/GTT%20exh%20man%2001.jpg[/img:0901d49371]

[img:567:378:0901d49371]http://www.renault-turbo.com/chris/GTT%20exh%20man%2002.jpg[/img:0901d49371]

[img:378:567:0901d49371]http://www.renault-turbo.com/chris/GTT%20exh%20man%2003.jpg[/img:0901d49371]

again I think I may remove the external casting flash, runner 1 needs a bit cleared up as theres a large bump in it for no reason, a casting flaw.

The carb I got did not look in the best health, dirty, corroded and oily

[img:567:378:0901d49371]http://www.renault-turbo.com/chris/GTT%20carb%2001.jpg[/img:0901d49371]

[img:567:378:0901d49371]http://www.renault-turbo.com/chris/GTT%20carb%2002.jpg[/img:0901d49371]

As it was so bad I decided blasting it clean would do no harm and I would then be able to strip it anyway, so after its wash

[img:567:378:0901d49371]http://www.renault-turbo.com/chris/GTT%20carb%2003.jpg[/img:0901d49371]

[img:567:378:0901d49371]http://www.renault-turbo.com/chris/GTT%20carb%2004.jpg[/img:0901d49371]

[img:567:378:0901d49371]http://www.renault-turbo.com/chris/GTT%20carb%2005.jpg[/img:0901d49371]

[img:567:378:0901d49371]http://www.renault-turbo.com/chris/GTT%20carb%2006.jpg[/img:0901d49371]

[img:567:378:0901d49371]http://www.renault-turbo.com/chris/GTT%20carb%2007.jpg[/img:0901d49371]

thats all the carb pictures, but I have totally stripped it to dry the water out and I will get it sparkling clean and rebuild it. Its missing its idle mixture screw though so I need to get one of those.

I pulled my inlet/exhaust man gasket out of the head set to try it on to see if I needed to do much port matching.

This is how the manifolds sit

[img:567:378:0901d49371]http://www.renault-turbo.com/chris/GTT%20manifolds%2001.jpg[/img:0901d49371]

gasket fitted

[img:567:378:0901d49371]http://www.renault-turbo.com/chris/GTT%20manifolds%2002.jpg[/img:0901d49371]

note not all stud holes are covered by the gasket, the gasket is also only gasket, not gasket and metal backing. So I need to get a decent gasket.

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

Well like I said last time the carb was stripped down, cleaned and rebuilt. I re-used the old stuff as there was no damage to it and it was all within spec.

I am however missing an idle mixture screw and fast idle screw. If you have one spare let me know!

For those that don't know the GTT version of the solex 32 BIS uses lip seals on the shafts, heavy duty re-enforced gaskets, the upper body is magnesium and the gasket face area is increased.

Carb top off the main body.

[img:567:378:86e7fdb89b]http://www.renault-turbo.com/chris/GTT%20carb%20strip%2001.jpg[/img:86e7fdb89b]

Carb main body

[img:378:567:86e7fdb89b]http://www.renault-turbo.com/chris/GTT%20carb%20strip%2002.jpg[/img:86e7fdb89b]

this is the carbs throttle body, not the water connections on the carb base

[img:378:567:86e7fdb89b]http://www.renault-turbo.com/chris/GTT%20carb%20strip%2003.jpg[/img:86e7fdb89b]

main body with power valve and full load enrichment valves removed

[img:567:378:86e7fdb89b]http://www.renault-turbo.com/chris/GTT%20carb%20strip%2004.jpg[/img:86e7fdb89b]

main body again but air corrector removed, accel pump jet removed etc etc

[img:567:378:86e7fdb89b]http://www.renault-turbo.com/chris/GTT%20carb%20strip%2005.jpg[/img:86e7fdb89b]

Anyway it all went back together all nice and clean. I even fitted it to the inlet manifold and fitted the brackets on that for the throttle linkage, forgot to get a pic though Rolling Eyes

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

I also have Alans turbo here as well, so I cleaned that up a bit for him and took it apart, theres gonna be a knowledge base article on it shortly folks.

Here is how it mounts on the mamifold

the back of it

[img:567:378:54e09a1d78]http://www.renault-turbo.com/chris/GTT%20turbo%20and%20man%2001.jpg[/img:54e09a1d78]

and the head face side

[img:567:378:54e09a1d78]http://www.renault-turbo.com/chris/GTT%20turbo%20and%20man%2002.jpg[/img:54e09a1d78]

the manifold is quite a poor casting theres lots of flaws in it, these will be removed to improve flow.

Better flow means more power and better response!

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

I received a GTT fuel pump today

[img:567:378:93d7c6fd6e]http://www.renault-turbo.com/chris/GTT%20fuel%20pump.jpg[/img:93d7c6fd6e]

it works as well which is nice.

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

I was at the factors today and got as good price on new decent discs, Â£30 for 238mm vented RSi discs.

This means RSI spec, not quite 16V but good enough.

The main thing is they will fit behind 13's, so the turbo'd beast will retain its pos look.

The car is coming out of service soon as the clio has arrived, it just needs to be mot'd etc so the red car can come off and get stripped.

Heres a pic of the new discs

[img:::3ee563f6e5]http://www.renault-turbo.com/chris/new%20vented%20238's.jpg[/img:3ee563f6e5]

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

Today my calipers arrived, so I am ready to stick the RSI brakes on this bad boy.

Heres a pic of the boot

[img:567:378:d0f5fab853]http://www.renault-turbo.com/chris/red%20boot%20spares.jpg[/img:d0f5fab853]

top clockwise, new brake discs, in the bag calipers and carriers with free'd off nipples, rear silencer which fell off last week - lol and new pads.

I might get the brakes on tomorrow, I couldn't be bothered today, was so busy with other cars.

Other than that nothing is happening, its radio is now in the clio, the dust is settling inside it etc etc. No more turbo bits as I am skint and I need to get the bloody blue hatch sorted first!

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

well I had to buy a backbox for the car as it needs to be able to be sold.

So today I fitted a new backbox also refitted the spare wheel carrier qand chucked in a good spare wheel.

[img:567:378:2243d43c6c]http://www.renault-turbo.com/chris/red%20new%20exh%20and%20wheel%20carrier.jpg[/img:2243d43c6c]

Note cable ties, the rubbers have been paid for and I will pick them up tomorrow morning.

Looks like the turbo conversion will not go ahead due to personal difficulties.

Not saying it deffo won't just doesn't look like it.

The car is open to sensible offers as are the turbo parts I have accumulated.

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

Well plans have changed yet again!

No longer is the turbo idea going ahead mainly due to money issues.

I am instead, going to RSi it!

I could 16V it but thats not the point is it.

Cars and modifying them is purely and exercise to be different.

So the RSI engine it is then.

The plan is,

16V exhaust,
16V front subframe with the wider track and power steering,
16V fuel lines and tank,
fit the 16v dash loom to get trip comp,
exec door cards,
leather (why not),
16V rear axle,
RSi engine and box and ECU courtesy of u33db.

The RSI is pretty rare in 19 form and no RSI ph1's were ever made, so its going to be a real 1 off.

RSI power is 113bhp whcih is roughly double whats in the car at the moment.

The other benefit is the car is the base spec shell, no sunroof etc etc, so its pretty light.

The car will be no slouch thats for sure.

Also there is always the possibilty of that nice cheap swap to 2 litre laguna power...

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

Well today Dougal (u33db) came down and I fixed his Clio and improved it vastly I may add and I got the RSI engine etc as payment, he got a bargain!

What I got was pretty much everything I need, hes bringing me the gearbox next time as it never all fitted in his 1.2 clio Laughing

So far couple of issues, need to sort the loom, need a cambelt and the downpipe. The 16V one will not mate up to it depsite what i was told by someone...

This pic shows the ECU, ps pump, starter, alt etc and the downpipe

[img:567:378:12b0f5dc4d]http://www.renault-turbo.com/chris/RSI%20delivered%2001.jpg[/img:12b0f5dc4d]

RSI manifold, it was taken off so it would sit on the pallet

[img:567:378:12b0f5dc4d]http://www.renault-turbo.com/chris/RSI%20delivered%2002.jpg[/img:12b0f5dc4d]

The engine itself, need 19 cambelt covers

[img:567:378:12b0f5dc4d]http://www.renault-turbo.com/chris/RSI%20delivered%2003.jpg[/img:12b0f5dc4d]

[img:567:378:12b0f5dc4d]http://www.renault-turbo.com/chris/RSI%20delivered%2004.jpg[/img:12b0f5dc4d]

[img:567:378:12b0f5dc4d]http://www.renault-turbo.com/chris/RSI%20delivered%2005.jpg[/img:12b0f5dc4d]

Just to show it is an RSI lump, 4 injectors

[img:378:567:12b0f5dc4d]http://www.renault-turbo.com/chris/RSI%20delivered%2006.jpg[/img:12b0f5dc4d]

really looking forward to this.

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

Let us start off by talking about engines and removing them. This is not a dig at u33db either as he never removed the engine just bought it!

if you don't know what your doing don't fecking touch it.

Or at least read the haynes it tells you to unplug the loom.

Its a Renault not a Ford where the loom is attached to the dashboard so you have to unplug it from the loom.

You unplug the ECU and the brown connectors an a couple other plugs and the engine comes out with the loom attached. So theres no need to yank the loom out etc etc and generally make an arse of it to then look totally stupid after the event when you unplug the loom itself.

Anyway, first I started off with a light cleaning session, stuff out of the plastic box

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/rsi%20bits%2001.jpg[/img:8763b66963]

this is the alt/ps pump bracket cleaned up less the idler pulley, cleaned up very well, compare it to how it looks in the pic above

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/rsi%20bits%2002.jpg[/img:8763b66963]

this is the clio gearbox mounts cleaned up, no need for them in a 19 but I hate oily crap

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/rsi%20bits%2003.jpg[/img:8763b66963]

Now onto the loom. The one Timmy had a go at with a chainsaw.

Theres a load of pics here but I will put them all up anyway.

The main issue is its a clio loom, now it could work on the 19, but to get it factory I would need to make a new loom, if I use the clio loom then I need to cable tie things out of the way and run dodgy extension cables.

Starting from the ECU side a general overlook of the loom

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/RSI%20loom%2001.jpg[/img:8763b66963]

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2002.jpg[/img:8763b66963]

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2003.jpg[/img:8763b66963]

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2004.jpg[/img:8763b66963]

lot of wiring for not that big an engine!

Dougal had asked what this was, now I have seen it 1st person its the knock sensor wire

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2005.jpg[/img:8763b66963]

this cable is nowhere to be seen, its been broken off inside the main loom, what could it be? find out later!

[img:378:567:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2006.jpg[/img:8763b66963]

another broken wire, what could that be? Again later

[img:378:567:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2007.jpg[/img:8763b66963]

the loom unwrapped a bit and I find those wires, coolant gauge sender wires! Sender is still on the head with the rest of the wiring and plug!

[img:378:567:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2008.jpg[/img:8763b66963]

the other broken wire, reverse light plug

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2009.jpg[/img:8763b66963]

very end of the loom, this is what I have reasoned them to be, right white plug CTS, red ring and brown plug alternator, white wire white plug oil pressure light and the black plug - struggled here but only thing I can think of and the plug is wrong but radiator fan switch

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2010.jpg[/img:8763b66963]

oil level sender plug and earth ring terminal

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2011.jpg[/img:8763b66963]

top no plug cos wires are chopped reverse light, ring earth terminal and radiator fan power feed

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2012.jpg[/img:8763b66963]

clio battery earth (its in the engine bay on the clio) and the relay connecotrs and plugs to dash

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2013.jpg[/img:8763b66963]

the silver terminal is the battery positive terminal, the white ignition module power feed and tacho feed and the black crank angle sensor plug

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2014.jpg[/img:8763b66963]

throttle position sensor plug

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2015.jpg[/img:8763b66963]

from left, white wire solenoid feed, metal terminal starter power feed, grey crank angle sensor and the black lambda sensor

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2016.jpg[/img:8763b66963]

the coolant temp gauge wires

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2017.jpg[/img:8763b66963]

from left, chopped knock sensor wire, 4 grey injector plugs, black ICV plug and the white inlet air temp sender still with sender in it - broken of course

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2018.jpg[/img:8763b66963]

green map sensor connector

[img:567:378:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2019.jpg[/img:8763b66963]

charcoal canister plug

[img:378:567:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2020.jpg[/img:8763b66963]

and the end of the line ECU connector

[img:378:567:8763b66963]http://www.renault-turbo.com/chris/rsi%20loom%2021.jpg[/img:8763b66963]

The loom will be repaired.

I am on the look out for a proper 19 RSI loom which I would prefer to use for obvious reasons, same goes for the rsi downpipe.

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

Todays first task was to remove the plug and wire from the temp sender on the head and solder it back onto the loom.

Heres a pic of it done as I never got the camera until later on. Shaky pic but its th eone with the silver heatsleeve on it, all sorted and as new.

[img:567:378:9cbd65e604]http://www.renault-turbo.com/chris/RSI%20temp%20gauge%20wire%20fix.jpg[/img:9cbd65e604]

I then set about generally messing around with it, I need to wash it but didn't fancy getting wet. So I set to pulling the cambelt covers off.

From the look of things its the original belt and the bottom pulley had never been off, in order for me to crack it I had to use the crankshaft locking pin hole, thats a first for me, they usually come off fine.

Anyway as you can see the pulley has seen a bit of action

[img:567:378:9cbd65e604]http://www.renault-turbo.com/chris/RSI%20bottom%20pulley%2001.jpg[/img:9cbd65e604]

heres the back of it, quite a difference eh!

[img:567:378:9cbd65e604]http://www.renault-turbo.com/chris/rsi%20bottom%20pulley%2002.jpg[/img:9cbd65e604]

need to get that sorted along with the water pump pulley.

the covers off but top mount left on, I also had the alt/ps bracket on and thats its idler you can see

[img:378:567:9cbd65e604]http://www.renault-turbo.com/chris/RSI%20belt%20cover%20off%2001.jpg[/img:9cbd65e604]

bracket off and general front shot of engine

[img:378:567:9cbd65e604]http://www.renault-turbo.com/chris/rsi%20front%20of%20block.jpg[/img:9cbd65e604]

heres a pic of the TB, its very similar to the 16V item but NOT the same

[img:567:378:9cbd65e604]http://www.renault-turbo.com/chris/rsi%20tb%2001.jpg[/img:9cbd65e604]

a shot of the rear of the block, no exh manifold as u33db took it off to get it into the car

[img:378:567:9cbd65e604]http://www.renault-turbo.com/chris/rsi%20rear%2001.jpg[/img:9cbd65e604]

this is hidden by the starter, its etched with a "fricking lazzzer"

[img:567:378:9cbd65e604]http://www.renault-turbo.com/chris/rsi%20rear%2002.jpg[/img:9cbd65e604]

where the oil pressure sender will screw in, note no coolant jacket drain plug

[img:567:378:9cbd65e604]http://www.renault-turbo.com/chris/rsi%20rear%2003.jpg[/img:9cbd65e604]

inlet man off as well

[img:567:378:9cbd65e604]http://www.renault-turbo.com/chris/rsi%20rear%2004.jpg[/img:9cbd65e604]

inlet mani

[img:567:378:9cbd65e604]http://www.renault-turbo.com/chris/rsi%20rear%2005.jpg[/img:9cbd65e604]

exhust manifold on

[img:567:378:9cbd65e604]http://www.renault-turbo.com/chris/rsi%20rear%2006.jpg[/img:9cbd65e604]

inlet and exhaust on

[img:378:567:9cbd65e604]http://www.renault-turbo.com/chris/rsi%20rear%2007.jpg[/img:9cbd65e604]

manifold heatshield removed

[img:567:378:9cbd65e604]http://www.renault-turbo.com/chris/rsi%20rear%2008.jpg[/img:9cbd65e604]

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

Yesterday I picked the loom and found out where the wires go on the plug. Looks like they should mate up tp the 19 dash loom nicely.

So I am thinking of maybe seeing if I can fire the thing up on the clio loom if nothing else. Gonna need to run iffy wiring to the dash loom though.

The engine is also a F3PR768, which means its not 1794cc but 1783cc. 0.5mm difference in stroke between the engines.

No big deal but motivation to get a 2 litre...

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

Well today I started on the red car, exhaust system totally off and without damage to the studs on the manifold.

Also removed the arch liners, had a go at the bumper but its choosing to be awkward, so will deal with that later.

I had hoped I was clever enough to fit the injection rear loom, but no, so I need to rip it all out of the red car, poo is the technical term, not a bad job normally. But in a hot tin can its a nightmare!

The engine was round the front getting in my way so I decided to get it moved round the back, mounted on the stand and drained of oil

Here it is on the stand draining

[img:567:378:b2eea5556c]http://www.renault-turbo.com/chris/RSI%20oil%20drain%2001.jpg[/img:b2eea5556c]

[img:567:378:b2eea5556c]http://www.renault-turbo.com/chris/RSI%20oil%20drain%2002.jpg[/img:b2eea5556c]

[img:378:567:b2eea5556c]http://www.renault-turbo.com/chris/RSI%20oil%20drain%2003.jpg[/img:b2eea5556c]

[img:378:567:b2eea5556c]http://www.renault-turbo.com/chris/RSI%20oil%20drain%2004.jpg[/img:b2eea5556c]

So I have a lot to do but the weather is making it a tad hard to say the least.

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

Dougal as always a true gent and dropped off the gearbox to me on sunday.

So here is the beats in all its glory, very oily glory at that.

[img:567:378:f40f9b3e79]http://www.renault-turbo.com/chris/rsi%20box%2001.jpg[/img:f40f9b3e79]

The offside shaft was just pulled out of the inner CV leaving it on the box

[img:567:378:f40f9b3e79]http://www.renault-turbo.com/chris/rsi%20box%2002.jpg[/img:f40f9b3e79]

just need to knock the roll pin out, these can be terrible but this one came out easy

[img:567:378:f40f9b3e79]http://www.renault-turbo.com/chris/rsi%20box%2003.jpg[/img:f40f9b3e79]

the joint was semi corroded to the output shaft so need some tapping to get it moving but it came out in the end. The pin also came out in 1 piece which is very rare!

[img:567:378:f40f9b3e79]http://www.renault-turbo.com/chris/rsi%20box%2004.jpg[/img:f40f9b3e79]

Next i set about removing what was left of the speedo cable, thsi was a bit of a mission but got there in the end.

[img:567:378:f40f9b3e79]http://www.renault-turbo.com/chris/rsi%20box%2005.jpg[/img:f40f9b3e79]

speedo cable parts out of the box

[img:567:378:f40f9b3e79]http://www.renault-turbo.com/chris/rsi%20box%2006.jpg[/img:f40f9b3e79]

I said earlier I hope the reverse light plug was still on the box, guess what I was right!

[img:567:378:f40f9b3e79]http://www.renault-turbo.com/chris/rsi%20box%2007.jpg[/img:f40f9b3e79]

inside the bellhousing

[img:378:567:f40f9b3e79]http://www.renault-turbo.com/chris/rsi%20box%2008.jpg[/img:f40f9b3e79]

Whats left of the main engine earth braid

[img:567:378:f40f9b3e79]http://www.renault-turbo.com/chris/rsi%20box%2009.jpg[/img:f40f9b3e79]

That was all I done yesterday but today I done more, which I will put up shortly.

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

Today I decided to put the engine and box back together and fit the loom just to make sure I fixed it right - which I did.

First job was to clean the box and the engine. So I got very wet and they got very clean.

So it was off the stand with the engine

[img:378:567:1bca2ab051]http://www.renault-turbo.com/chris/rsi%20ass%2001.jpg[/img:1bca2ab051]

cleaner eh!

[img:378:567:1bca2ab051]http://www.renault-turbo.com/chris/rsi%20ass%2002.jpg[/img:1bca2ab051]

much cleaner if paintless

[img:567:378:1bca2ab051]http://www.renault-turbo.com/chris/rsi%20ass%2003.jpg[/img:1bca2ab051]

flywheel needed seen to

[img:567:378:1bca2ab051]http://www.renault-turbo.com/chris/rsi%20ass%2004.jpg[/img:1bca2ab051]

so it was cleaned up

[img:567:378:1bca2ab051]http://www.renault-turbo.com/chris/rsi%20ass%2005.jpg[/img:1bca2ab051]

the lower engine to box bracket tie bar thingy, this was a right oily mess, spotless now

[img:567:378:1bca2ab051]http://www.renault-turbo.com/chris/rsi%20ass%2006.jpg[/img:1bca2ab051]

clutch back on

[img:567:378:1bca2ab051]http://www.renault-turbo.com/chris/rsi%20ass%2007.jpg[/img:1bca2ab051]

nice clean box fitted to engine, compare it to the pics above, no more oil!

[img:378:567:1bca2ab051]http://www.renault-turbo.com/chris/rsi%20ass%2008.jpg[/img:1bca2ab051]

front view, note scrap pile in the background, what you can't see are the subframes etc, scrap man make me money. Also note ps pump and alt fitted

[img:567:378:1bca2ab051]http://www.renault-turbo.com/chris/rsi%20ass%2009.jpg[/img:1bca2ab051]

pullies, the 19 set up is nicer I have to say

[img:378:567:1bca2ab051]http://www.renault-turbo.com/chris/rsi%20ass%2010.jpg[/img:1bca2ab051]

fitting the loom

[img:567:378:1bca2ab051]http://www.renault-turbo.com/chris/rsi%20ass%2011.jpg[/img:1bca2ab051]

round the back

[img:567:378:1bca2ab051]http://www.renault-turbo.com/chris/rsi%20ass%2012.jpg[/img:1bca2ab051]

I then thought it was a good time to re-attach the cut off reverse light plug

[img:567:378:1bca2ab051]http://www.renault-turbo.com/chris/rsi%20rev%20plug%20fix%2001.jpg[/img:1bca2ab051]

[img:567:378:1bca2ab051]http://www.renault-turbo.com/chris/rsi%20rev%20plug%20fix%2002.jpg[/img:1bca2ab051]

perfect

[img:378:567:1bca2ab051]http://www.renault-turbo.com/chris/rsi%20rev%20plug%20fix%2003.jpg[/img:1bca2ab051]

more of the wiring loom

[img:567:378:1bca2ab051]http://www.renault-turbo.com/chris/rsi%20ass%2013.jpg[/img:1bca2ab051]

[img:378:567:1bca2ab051]http://www.renault-turbo.com/chris/rsi%20ass%2014.jpg[/img:1bca2ab051]

Only loom issue yet to be sorted is the knock sensor lead and I need to tape up the tubing wheres its fallen off. Might as well sort the loom out, still need a 19 one to use in the 19!

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

Today I removed the front mount bracketry from the dodgy 16V lump in the shed. This is the only way I have at the moment anyway of mouting the engine and the PS etc.

The front moiunt fitted

[img:567:378:317c67e395]http://www.renault-turbo.com/chris/rsi%20front%20mount%2001.jpg[/img:317c67e395]

the clean small one is the 16V pulley, quite a size difference eh!

[img:567:378:317c67e395]http://www.renault-turbo.com/chris/rsi%20front%20mount%2002.jpg[/img:317c67e395]

the 16V pulley won't even fit due to the cambelt cover, I could mod it but don't want to.

[img:567:378:317c67e395]http://www.renault-turbo.com/chris/rsi%20front%20mount%2003.jpg[/img:317c67e395]

the engines a good bit deeper with the 19 gear on it!

[img:567:378:317c67e395]http://www.renault-turbo.com/chris/rsi%20front%20mount%2004.jpg[/img:317c67e395]

I have an issue with the crank pulley, the 16V PS pump has a smaller pulley to match the smaller crank pulley, thismeans with the large RSI crank pully the PS will be over assisted, it shouldn't be a problem as an RSi doesn't need loads of revs anyway.

Another issue I have chosen to ignore cos it will be a problem is the fact its a ph3 rsi lump, means its only got 1 tooth on the flywheel opposed to the 2 teeth. This means with a 19 RSI ECU it MIGHT only fire on 2 cyls so I may need to change the flywheel.

On the flipside that means I have to fit a 16V one which is lighter so that will help its response. Also means faster accel and it will further close the gap between the RSI and 16V.

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

today I shoved the exec out into the street and cleaned the subframe down.

Thanks to the oil leak (see the oil leak thread in pics and vids) the drivers side of the subframe is immaculate as this pic shows

[img:567:378:40a29fc0a2]http://www.renault-turbo.com/chris/exec%20subframe%20wash%2001.jpg[/img:40a29fc0a2]

Passenger side less oil leaks more scabbiness, no holes or anything though

[img:567:378:40a29fc0a2]http://www.renault-turbo.com/chris/exec%20subframe%20wash%2002.jpg[/img:40a29fc0a2]

much cleaner so I won't mind handling it so much when it comes off to go on the red car.

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

Got busy today.

First thing I did was removed the back box from the exec then cleaned it then stuck it on the red car.

I fecking love it, looks great in an 80's dustbin kinda way! It will go in a bit and sit straighter when the rest of the exhaust is on.

[img:567:378:4dc4b70805]http://www.renault-turbo.com/chris/red%2016V%20backbox%2001.jpg[/img:4dc4b70805]

in this next pic look at the skinny 13, this will be replaced with the nice 15's.

[img:567:378:4dc4b70805]http://www.renault-turbo.com/chris/red%2016v%20backbox%2002.jpg[/img:4dc4b70805]

I started stripping the exec today to put the looms into the red car, of course the exec is a gay ph2, wiring is pish and totally different.

So instead I fitted the black seatbelts from the exec and the rear door cards and had to DIY the loom.

The belts and card, still not sure about the cards, some people have said they want them and they would get back to me, still waiting.

[img:567:378:4dc4b70805]http://www.renault-turbo.com/chris/red%20exec%20belts.jpg[/img:4dc4b70805]

Anyway wiring loom, problem, I was missing the fuel pump power feed and earth.

Original plan was use exec loom, won't go, then I tried to find my old ph1 16V rear loom, couldn't find it. So only 1 option, do it myself and do it properly!

this sorry pile of wires was the original dash loom for the red car back before I stuck the gts-x dash into it.

[img:567:378:4dc4b70805]http://www.renault-turbo.com/chris/red%20efi%20wiring%2001.jpg[/img:4dc4b70805]

I needed the longest thickest wire I could use, this turned out to be the starter solenoid wire and it was also white - the correct colour.

I also needed a fuel pump plug, the superior ph1 headlight system when on sidelights puts the headlights on dimly via a resistor in the scuttle. This connector had relatively beefy wiring and fits properly in the pump, so I shopped it off as this pic shows.

[img:567:378:4dc4b70805]http://www.renault-turbo.com/chris/red%20efi%20wiring%2002.jpg[/img:4dc4b70805]

this pic shows the white solenoid wire and I also picked the thickest earth lead as well, turned out to be for the window wipers. I of course unpicked the pin and the ring terminal so they are as standard.

[img:567:378:4dc4b70805]http://www.renault-turbo.com/chris/red%20efi%20wiring%2003.jpg[/img:4dc4b70805]

power feed plugged into the connector, look at the size of that

[img:567:378:4dc4b70805]http://www.renault-turbo.com/chris/red%20efi%20wiring%2004.jpg[/img:4dc4b70805]

as its hidden I just put it through the clips instead of taping it all the way along, some size eh!

[img:567:378:4dc4b70805]http://www.renault-turbo.com/chris/red%20efi%20wiring%2005.jpg[/img:4dc4b70805]

I ran it through the plastic before the arch though and let it exit the way it should with the sender wires

[img:567:378:4dc4b70805]http://www.renault-turbo.com/chris/red%20efi%20wiring%2006.jpg[/img:4dc4b70805]

I then ran the earth to the back panel as it is on the cars.

So thats the wiring pretty much sorted, just need top attach the plug to the wires after I cut it to size which I will do when I go to fit the tanks, no point in having it to long.

The wire sizes are thicker than stock so there should be no voltage drop issues to the pump.

I also got the front bumper off today

[img:567:378:4dc4b70805]http://www.renault-turbo.com/chris/red%20bumper%20off.jpg[/img:4dc4b70805]

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

Well today I changed the fuel lines and the tank to the efi set up from the exec. Sadly the tank has pinholes around the filler stub, so need a decent tank but that can wait.

anyway some pics

The efi tank, you can easily tell as theres 2 things on the top, on the left the pump on the right (and under the cap in the boot) the level sender.

[img:567:378:f7481b9e22]http://www.renault-turbo.com/chris/red%20efi%20tank%2001.jpg[/img:f7481b9e22]

pulled the pump to make sure the gauze wasn't blocked, you can see the grit inside, thats the rust from the tank.

[img:567:378:f7481b9e22]http://www.renault-turbo.com/chris/red%20efi%20tank%2002.jpg[/img:f7481b9e22]

hard to see in this pic but theres pinholes. About 15mm up from the top of the stub and 15mm in from the right of the pic, you can just make out a pinhole

[img:378:567:f7481b9e22]http://www.renault-turbo.com/chris/red%20efi%20tank%2003.jpg[/img:f7481b9e22]

here we have the fuel feed, return and charcoal canister line, all cleaned up and shiny

[img:378:567:f7481b9e22]http://www.renault-turbo.com/chris/red%20efi%20tank%2004.jpg[/img:f7481b9e22]

Here we have the loom for the fuel pump, now looks all standard

[img:567:378:f7481b9e22]http://www.renault-turbo.com/chris/red%20efi%20tank%2005.jpg[/img:f7481b9e22]

Today I also found the 16V loom I was looking for the other day - typical.

Here is a vid I took of the 1.4 engine and this is the last time it will ever run in this car anyway, all it ran on was what was left in the carb, no exhaust or anything attached, 10meg

http://www.renault-turbo.com/chris/red%201.4%20engine%20last%20ever%20run.MOV

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

Today I got busy.

This overexposed pic is of the steering column, maual rack, you access the pinch bolt from inside the car, a lovely job

[img:567:378:557349058b]http://www.renault-turbo.com/chris/red%20manual%20column%20pinch%20bolt.jpg[/img:557349058b]

column removed

[img:567:378:557349058b]http://www.renault-turbo.com/chris/red%20column%20removed.jpg[/img:557349058b]

the subframe removed from the exec

[img:567:378:557349058b]http://www.renault-turbo.com/chris/16V%20subframe%20removed.jpg[/img:557349058b]

red cars subframe dropped

[img:567:378:557349058b]http://www.renault-turbo.com/chris/red%20subframe%20dropped%2001.jpg[/img:557349058b]

another angle

[img:567:378:557349058b]http://www.renault-turbo.com/chris/red%20subframe%20dropped%2002.jpg[/img:557349058b]

How I got extra height to get the shell to clear the engine and subframe, DON'T try this at home kids, I am a professional idiot with years of training.

[img:567:378:557349058b]http://www.renault-turbo.com/chris/red%20subframe%20dropped%2003.jpg[/img:557349058b]

here is the manual and the power steering column's side by side, the lower one is the manual and its a non adjustable one.

[img:567:378:557349058b]http://www.renault-turbo.com/chris/manual%20and%20power%20steering%20column.jpg[/img:557349058b]

clutch cable where it passes into the bulkhead, note the split on the grommet

[img:567:378:557349058b]http://www.renault-turbo.com/chris/red%20clutch%20cable%20bulkhead.jpg[/img:557349058b]

the view an engine gets

[img:567:378:557349058b]http://www.renault-turbo.com/chris/red%20be%20the%20engine.jpg[/img:557349058b]

column gaiter fitted properly

[img:567:378:557349058b]http://www.renault-turbo.com/chris/red%20column%20gaiter%20fitted.jpg[/img:557349058b]

rear subframe mount, all the rubbish was cleaned out

[img:567:378:557349058b]http://www.renault-turbo.com/chris/red%20rear%20subframe%20mount.jpg[/img:557349058b]

my cleaned fuel lines, this is where the hard plastic lines finish

[img:567:378:557349058b]http://www.renault-turbo.com/chris/red%20fuel%20lines%20end.jpg[/img:557349058b]

I had to fit a fuel filter and bracket

where they both live

[img:567:378:557349058b]http://www.renault-turbo.com/chris/red%20efi%20fuel%20filter%2001.jpg[/img:557349058b]

new filter

[img:378:567:557349058b]http://www.renault-turbo.com/chris/red%20efi%20fuel%20filter%2002.jpg[/img:557349058b]

fitted to the lines

[img:567:378:557349058b]http://www.renault-turbo.com/chris/red%20efi%20fuel%20filter%2003.jpg[/img:557349058b]

bracket fitted, all as factory

[img:567:378:557349058b]http://www.renault-turbo.com/chris/red%20efi%20fuel%20filter%2004.jpg[/img:557349058b]

16V front brakes

[img:567:378:557349058b]http://www.renault-turbo.com/chris/red%2016V%20brakes.jpg[/img:557349058b]

charcoal canister mounted, yes I broke the lower stud, not a problem though.

[img:567:378:557349058b]http://www.renault-turbo.com/chris/red%20charcoal%20canister%20fitted.jpg[/img:557349058b]

bay view showing the ps bottle mounted and ps fluid coller mounted etc

[img:567:378:557349058b]http://www.renault-turbo.com/chris/red%2016V%20sub%20fitted.jpg[/img:557349058b]

Just needs the engine fitted, the exhaust and some fuel.

Forum Moderator Joined: 02 Mar 2004 Posts: 19978

first job today was to fit the nearside 16V caliper, or more correctly plumb it in. The union put up a struggle and the hose was damaged.

So its now sporting a nice new hose as well

[img:378:567:bd04352ce5]http://www.renault-turbo.com/chris/red%20ns%2016V%20caliper.jpg[/img:bd04352ce5]

I then set about changing the master cyl set up to the 16V style.

[img:567:378:bd04352ce5]http://www.renault-turbo.com/chris/red%2016v%20master%2001.jpg[/img:bd04352ce5]

[img:567:378:bd04352ce5]http://www.renault-turbo.com/chris/red%2016V%20master%2002.jpg[/img:bd04352ce5]

I need to sort out fixings for the fluid resovoir. As the studs are missing on the non 16V's.

[img:567:378:bd04352ce5]http://www.renault-turbo.com/chris/red%2016V%20master%2003.jpg[/img:bd04352ce5]

The C-type engine used this crappy air intake mounted on the nearside inner wing, where the 16V aux water pump relay bolts up.

[img:567:378:bd04352ce5]http://www.renault-turbo.com/chris/red%20ai%2001.jpg[/img:bd04352ce5]

Sadly I don't have a ph1 16V surround with the air intake on that so I have resorted to the ph2 slam panel air intake effort.

screw clips fitted ready for the snorkel to be bolted up

[img:378:567:bd04352ce5]http://www.renault-turbo.com/chris/red%20ai%2002.jpg[/img:bd04352ce5]

screwed in

[img:567:378:bd04352ce5]http://www.renault-turbo.com/chris/red%20ai%2003.jpg[/img:bd04352ce5]

Also fitted the coolant header tanks bracket up and fitted all the heatshields etc just to get the look of it. It all needs to come back out to fit the engine anyway.

[img:567:378:bd04352ce5]http://www.renault-turbo.com/chris/red%20bay%20pre%20engine%20install.jpg[/img:bd04352ce5]