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Page 4- IHI is inside

After long time - it's time to update this page , some very interesting things happened in last few months - too summarize shortly, Marin throw away old 1.3 Uno Turbo engine and dropped 1.6 Fiat SOHC that was prepared long time ago for turbocharging - but before bolting turbo, we decided to tune N/a part of VE tables in Megasquirt, so we instaled again Megasquirt, put 190cc high-impedance injectors and made about 1600 km without any problems - Megasquirt tuned easily using LC-1 wideband controler and car runs great !

But everything comes to an end - so when Marin was satisfied with N/a and decide for little more kick, he decide that's turbo time - so he again dismantled intake manifold and started his main project - to turbocharge his 1.6 engine. He had IHI RHB5 turbo together with manifold from his old 1.3 Uno Turbo, so he used that for a start - in the future he will probably mount T3 with some large trim to see maximum from this engine.

But instalation wasn't so easy - we expected some problems with mounting turbo , of course - original downpipe had been cut, and new downpipe was welded in place.

We made completely new exhaust system from junkyard parts - it's not looking very fancy, but it will serve its purpose.

This IHI has very good turbo exit flange with separate hole for wastegate discharge -so we made separate pipe vented to atmosphere to use that possibility.

NOTE: CLICK ON THUMBNAILS ON THE LEFT TO OPEN LARGER IMAGE !!! (1024X768 PIXELS)

 

Marin's first job was to cut front end of his car so he can mount big Volvo IC and coolant radiator from Uno Turbo.

... after some cutting...

...IHI RHB5 is in place - there is problem with clearance from firewall, so new downpipe has to be made...

...this is downpipe after some tweaking - it has to be away at least 2cm from right half shaft.

...Volvo IC & Uno Turbo radiator will be mounted as one piece unit - after cutting, job wasn't finished yet, headlights had to be removed and then again some fine cutting and grinding was needed...

 

Complete exhaust with flexi joint - Marin wanted simplest exhaust possible with relatively quiet sound so we put one straight-through muffler on the back...turbine backpressure acts like very good muffler , especially with small turbo like this IHI...

...some people in garage can't even work on Fiats without official Fiat clothing ;-)

...Marin always insist that his car must retain street sleeper look - so Fiat front plastic grille has to go back and some sheet metal has to be welded back...front bumper also is going back in its place...

..I adviced Marin to put aluminium heat shield for turbo - it's good and simple solution for reducing underbonnet temperatures - and curious fingers can't be burnt so easily anymore when working on nice hot turbo :-))...

...another shot ...

Intercooler piping was relatively straightforward job - biggest problem was with finding cleanest & simplest path for instalation.

 

...this is custom 15 L fuel cell that will be mounted in the trunk - electric fuel pump will be mounted securily underneath and std 6 & 8 mm fuel instalation would be used for rest of the system...

...this are two double coils - after approx. 3 days of constant fighting with ignition& software problems, we finaly started car powered with 4-1 crank wheel together with two ignition modules and two double coils - wasted spark works on Fiat with Megasquirt - yeaaahhhh!!!

No more distributor problems - Marin almost cried like a baby when he finaly saw his car idling with 2 double coils, I almost cried too :-)

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