sburrell's dci 100

[Martin_172]

mine lasted about a year and 20k but that was hard hard driving, i think as long as you let the torque come in a bit slower rather than sinking the boot in a high gear all the time it will be fine as mine only slipped at 2000rpm until 2500rpm then you could get the boot down and it was fine.

however i sold it at about 80k and a mate stumbled across the guy who had bought it after me from auction and it was stil going strong at 140k on the same clutch he didn't drive it quickly!

 

[sburrell93]

Sounds similar to how the clutch in my brothers old pug 306 used to be when it was mapped to 250lb/ft and 150hp lol. Manageable, but just slipped a little sometimes.

Tempted to just go full power now. I do about 15-20k miles a year, but it's mainly motorway driving and I just fire the cruise control on and sit at a constant speed.

I'm on 108k miles just now though and have no idea if it's the original clutch. Biting point does seem high on it but I'm not sure if that's normal with the hydraulic clutch. Could do without the costs of replacing the clutch in it but the power is just far too tempting!

 

[Dr HMS Derv Destroyer]

Mines slipping as it comes on peak torque then is fine after. And that's on a 35k old clutch.

cant wait to sort out my intercooler and get a Mondeo pump fitted.
Then IT WILL destroy the clutch lol

might see if I can find a way to overfill my gearbox to handle more torque

 

[Martin_172]

Best bet would be to get a spare jc5 and just have it rebuilt ready to swap over when it brakes then when that happens just rebuild the broken one and repeat all over again lol thays my plan for my turbo 172 when i build it

 

[sburrell93]

Mines slipping as it comes on peak torque then is fine after. And that's on a 35k old clutch.

cant wait to sort out my intercooler and get a Mondeo pump fitted.
Then IT WILL destroy the clutch lol

might see if I can find a way to overfill my gearbox to handle more torque

I'll just go full power and hope for the best lol. If it slips, it slips. Just hope it's useable for motorway driving and if it is I'll just live with it lol.

What power are you hoping for with the mondeo pump fitted?

 

[Martin_172]

Its perfectly usable just drive around it, it was only 4th and 5th gear at 2000-2500rpm on full throttle i had issues, can always uprate it if needed!

 

[Dr HMS Derv Destroyer]

Yeah I'm using mine til the clutch pops.
If I don't give it hell, it's usually fine.

Hope to get 150/160 with the Mondeo pump, injector nozzles already changed.
Think my hybrid turbo maybe out off puff tho.

 

[Dr HMS Derv Destroyer]

Best bet would be to get a spare jc5 and just have it rebuilt ready to swap over when it brakes then when that happens just rebuild the broken one and repeat all over again lol thays my plan for my turbo 172 when i build it

Yeah plan was to get another box cryo treated and uprated syncs ( if they run then ) possibly a taller 5th from another JC5 Veriant

 

[AlexW]

Went to see about getting a remap last night. Tried a place just local to me with a pretty decent rep. Was quoted £250 for a live map on a RR which includes a before and after power run. Anyone know if that's a good or bad price?

If I go ahead with it, he said they could try and fit me in at some point at the beginning of next week. Can't wait to get it mapped now!

If thats a live map, and not a overlay map, that is good. I got quoted £230 by a specialist, without RR.

Overlay maps can cause richness, and leanness, Morso the former, but still not right!

 

[sburrell93]

As far as I'm aware it's live mapping. I think technically he uses a template map but the RR is definitely used to tweak the map to suit the car, so I'm assuming it's pretty much the same as a live map.

I didn't realise stuff like that mattered too much on a diesel, since there's no set air/fuel ratio as such with it just being a case of more throttle = more fuel

 

[Dr HMS Derv Destroyer]

Thorracing mapped mine from the original map. They offloaded it from the car and then adjusted it.

Took them 6 hours on their hub dyno to get it how I want.

Think I payed nearly £300

 

[AlexW]

As far as I'm aware it's live mapping. I think technically he uses a template map but the RR is definitely used to tweak the map to suit the car, so I'm assuming it's pretty much the same as a live map.

I didn't realise stuff like that mattered too much on a diesel, since there's no set air/fuel ratio as such with it just being a case of more throttle = more fuel

You can still run a Diesel lean, or bloody rich. Any black smoke is rich, Off boost a bit is acceptable, on boost it shouldn't smoke at all. My Black DCi (Overlay remapped) smokes constantly, only slightly, but it annoys me.

EGT sensors are great on Diesels, as you can keep an eye on whats happening, Anything up to 600ish is fine, over that you'll start melting pistons etc.

 

[Dr HMS Derv Destroyer]

Yupp got my EGT fitted on the downpipe just after the turbo. Should really be in the manifold mind.

I can get mine to spike past 600 if I floor it like a tw*t at Mallory race track. And this time I'm not going max fuel. Learnt my lesson on engine number one, managed to cook the head , with the amount of boost rammed into it

Defo get the EGR taken out the map. That's why the guys at Thor took longer to do mine, the fuel graph had to all be re-written to make the EGR nothing

 

[sburrell93]

You can still run a Diesel lean, or bloody rich. Any black smoke is rich, Off boost a bit is acceptable, on boost it shouldn't smoke at all. My Black DCi (Overlay remapped) smokes constantly, only slightly, but it annoys me.

EGT sensors are great on Diesels, as you can keep an eye on whats happening, Anything up to 600ish is fine, over that you'll start melting pistons etc.

Ahh yeah, I somehow managed to forget that overfuelling and black smoke is exactly what running rich is. It's late...that's my excuse!

I don't mind a little bit of black smoke on hard acceleration, would prefer that to having the car running lean and overheating things. If it was smoking constantly like the way mapped PD engines tend to though, it would annoy me too.

Yupp got my EGT fitted on the downpipe just after the turbo. Should really be in the manifold mind.

I can get mine to spike past 600 if I floor it like a tw*t at Mallory race track. And this time I'm not going max fuel. Learnt my lesson on engine number one, managed to cook the head , with the amount of boost rammed into it

Defo get the EGR taken out the map. That's why the guys at Thor took longer to do mine, the fuel graph had to all be re-written to make the EGR nothing

Yeah will defo be getting mapped out. Decided to plug mine back in tonight just to see if it was actually fecked or if it would fix itself with some foot to the floor action. 15 minutes of failing to get any power when I want it and piles of black smoke every other time I tried (and failed) to accelerate meant it was swiftly unplugged again lol.



You guys any idea what the max safe boost is on the 100 turbo? More out of curiosity than anything

 

[RenMatt]

£230 sounds good for the rolling road set up , I paid £300 for the one on my megane & was not impressed , no rolling road so no before and after , done outside in there car park & yes it felt quicker but it also killed the mpg wen t down from a constant 62 mpg to around 45 & even driven with a careful right foot would barely do 55 mpg :dapprove: sort of wished I had left it alone . Good luck with your map & look forward to seeing the results

 

[Martin_172]

Does sound suspect too cheap for a live map i paid 500 quid to have my twingo tce done at rs tuning

 

[sburrell93]

It's definitely done using a RR. Although after a bit of googling I don't think it's likely to be a fully live map. Probably more chance of it being a generic map that's then customised slightly to suit the car using the RR

 

[Dr HMS Derv Destroyer]

Max safe boost on the BV39 for the first gen 100's is near 2bar with mega cooling.
You will not get that on the Delphi set up tho, not enough fuel to help it

 

[Dr HMS Derv Destroyer]

Yours whilstle louder than mine and AlexW's as your turbo is a BV not a KP

you have VNT and we have waste gate

 

[sburrell93]

VNT FTW! The whistle sounds epic.

Love the noises you get when you lift off at certain rpm's with vnt's as well

 

[Tutuur]

When tuning my dci i came to the point where i got no more air in, boost is now 1.3 bar, anything higher and the maf just wouldn't read more. I then fooled the smoke map but as the name says, it became a smoke map.

Now have it pretty much tuned as i like, not too much time spent and could probably be better but it runs fine, it does smoke a bit on full throttle but mines on 170k miles atm. Clutch too btw and with the current power it isn't slipping. Warning light regarding fueling only comes on flooring it in 5th on warm days so i'm around the limit of the fueling system.

 

[Martin_172]

that's good going on the clutch, mine was dead by 70k or there abouts, mapped since 40k

 

[sburrell93]

Finally took the decision to get my 172 alloys refurbed. Dropped them off to get powdercoated yesterday at Fife Powdercoatings, going to pick them up next Friday as I'm working away during the week just now. Looking forward to finally getting them on the car, just need some tyres first!

Lost a lot of interest in the car over the past month or so really, started looking into new cars, but after dropping the wheels off yesterday I'm getting back into it a bit. Still haven't got round to getting the car mapped, so that will hopefully get done soon.

 

[sburrell93]

Went in early Friday morning to pick up my wheels. They weren't quite ready, so I waited around a couple of hours until they were out the oven and cooled down.

Definitely worth the wait. There were two of the wheels that were too corroded to repair fully, so there's a slight pitting in those, but overall the wheels look fantastic! Guy told me if I can find another two better condition wheels that I can replace the bad ones with, he would refurb them for me for nothing. Can't say fairer than that! Would definitely recommend them.

As soon as I picked the wheels up I went and got a set of tyres on them and got the wheels fitted as I was driving 180 miles up north that day and really needed new tyres. Got 4 Kumho KH31's on them, and so far can't fault them for the price. £270 fitted for the 4 of them!

Anyway on to a few crap iPhone photos

Shiny!

And fitted, minus the centre caps

Going to try and get some proper photos later in the week, rather than terrible iPhone ones!

 

[AlexW]

Non-sports look so good just lowered on 172's.

Get the tyre lube off and blacked and it'll look mint.

 

[sburrell93]

Non-sports look so good just lowered on 172's.

Get the tyre lube off and blacked and it'll look mint.

Cheers, I'm really liking the look. Can't help but feel the front end needs something else though. The rear looks fine with the sport bumper but there's nothing for the front.

The tyre lube got wiped off not long after that photo! Was already 2 and a bit hours late for leaving to drive away up north on holiday lol so was all very rushed! Can't wait to get home and get some megs tyre gel on it though.

 

[RenMatt]

Looking good , was all ways going to try the newer style campus sport front bumper on one as there is no wing modifications required Would show of the intercooler nicely & with the right bottom splitter I think it would loo sweet

 

[sburrell93]

Looking good , was all ways going to try the newer style campus sport front bumper on one as there is no wing modifications required Would show of the intercooler nicely & with the right bottom splitter I think it would loo sweet

That might be a good plan! Tempted to source a cheap campus bumper now and see how it looks. I'm not sure what campus one I prefer though (if the images I'm googling are right anyway lol)

 

[sburrell93]

Not done much with this lately, but a quick polish using my mates DA on Sunday has brought back a bit of love for the car.

So I bought this

Going to get the pipework ordered this week and hopefully get it fitted at the weekend.

Also got some colour coded door handles coming. Bargain off eBay at a tenner! Will probably colour code the front bump strips soon too. Although that might turn into a front end respray, going by the state of my front bumper!

More pics soon hopefully

 

[AlexW]

Boom!

I can give you tips on fitting that too if you like.

 

[Dr HMS Derv Destroyer]

i have finally ordered all the pipe work to do mine. 2'' SS for hard pipes :evil:
hybrid has arrived back this week after allot of arguing who's fault it was for the last one shitting itself.

oh and the newer K9K delphi pump on order same bolt pattern, but better set up inside the pump.... hello more fuel

 

[sburrell93]

Boom!

I can give you tips on fitting that too if you like.

Cheers man, might need it! Been sizing it up tonight.

Going to have to mount it slightly off centre as the current pipe work won't allow it to sit central.

Bit hard to explain and I never got pics, but essentially the return pipe comes down at a 45 degree angle and attaches to the intercooler. If I sit the new IC central on the front of the car, the outlet of it sits right in line with the 45 degree angle of the current pipework, so leaves no room to get the bend in and connect it up. So I'll have to sit it over to one side. Will go on easy that way with 45 and 135 angle hoses, but it'll look odd.

Any suggestions are welcomed lol

 

[AlexW]

Mines central, and clearly win, but it required massives of pipes, 180 degree, 90 degree x2 etc.

Off central is how a lot of the Turbo 1*2's are, My mates Engine Dynamics is like that anyway.

 

[sburrell93]

i have finally ordered all the pipe work to do mine. 2'' SS for hard pipes :evil:
hybrid has arrived back this week after allot of arguing who's fault it was for the last one s**tting itself.

oh and the newer K9K delphi pump on order same bolt pattern, but better set up inside the pump.... hello more fuel

Ooooooh more fuel you say? Do go on! I thought the injectors still limited these on power, or are am I missing something and you're running different injectors?


Edit: Alex, I considered just getting SS pipe and redoing the whole pipe from the intercooler back to the egr, just to get it sitting central lol, but that's a bit more than I really want to spend! Looks like it'll just have to sit off centre

 

[Dr HMS Derv Destroyer]

my ' special injectors ' ( hdi nozzles ) are currently in a box as i thought they was causing my cold start issue ( long story after checking almost everything )

so im now on pov spec 80's ( still goes like a rocket mind )

the newer pumps are built different, according to the delphi site, they have slightly bigger pistons and a better intake/return set up.
still finding out if it needs an intank pump ( i hope it does , as it means its less likely to do the common low pick up cog shitting itself and thowing metal into everything )

 

[Dr HMS Derv Destroyer]

i cant find the photo of it, but it has the same three mounting holes. the fuel inlet banjo but the return isnt connected to the injector returns anymore.
the pump return is also on a banjo on the side, and the leak back from injectors goes to some little black tubes at the top of the pump.

2013 k9k fuel pump.

 

[sburrell93]

I'll have a look into that, cheers! My injectors were recon'd at 50k miles, pump is still the original one though as far as I'm aware, so a new pump probably isn't a bad idea.

Although tbh I can see myself just getting it mapped as it is and living with the 120-130hp it'll put out, while keeping an eye on the pump. If it starts to let go I'd just get it whipped out and replaced asap and hopefully save the injectors.

 

[Dr HMS Derv Destroyer]

thats what i thought when my first pump went, but the dash lights come on way to late to save anything. the damage s already done

 

[sburrell93]

Well it'll make a good excuse to buy a 182 if it does die haha!
AlexW where did you get all your hoses and pipework? Ideally I need a 57-51mm 135 degree reducer but I can't find one anywhere!

 

[Dr HMS Derv Destroyer]

I thought it's be easier to do it with a 100 set up already? The 80's have a rather odd top angle to match to