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stock 13B-REW swapped FC
Its been some time , but lets try something new.
My latest FC, purchased in summer 2017 as roller. 1988 S4 TII , euro spec Bad paint, few rust spots, 230 000km's or so on gauges. Not much in engine bay, but over 18 years i have collected some parts, no big deal. Over the 2017 in breaks between other projects and work i did some cleaning, body work, replaced both doors, rear bumper and tried to get a paintjob done by someone. In beginning 2018 i removed newly built 13B-REW from white FD racecar, stripped it and started dressing it up into stock 1993 EU spec twinturbo. EU harness, EU solenoids, EU ECU and harness Ported wastegate and installed 90-85 fan switch. Oil pan brace installed. Next step was to build patch harness which makes install sort of plug & play, keeping FD emissions harness untouched , as well cars harness untouched. And last step so far was bolting up transmission (s4 TII), stock downpipe/precat and mock it up on FC subrame to see if it will fit into bay and where engine mounts will be. Evening ended with engine mount provisions on subframe tacked up, to be continued. |
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some pics
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more pics
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more pics from the past
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Last few pics, ending yesterday......test fitting dressed up block and modifying subframe for FD mounts....
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today i spent few hours reinforcing engine mount positions on subframe, still need to make notch for turbo control actuator in there.....
as well, moved one of the PS hardlines little bit lower engine even with precat clears, but tolerance is very tight, not much space for heatshield close to precat... stock harness should work fine |
Great to see another FC saved! Nice work, sir!
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Clean build!! What made you want to leave the FD engine completely stock with emissions? That's unique in itself LOL.
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Seconded. It looks like you're doing a great job, but why go to the trouble of swapping an REW in if you are only going for stock power? And with full emissions, no less? It seems like you could put in a 13BT and just do exhaust and a standalone and make almost the same power. Or alternatively, upgrade to a hybrid or aftermarket turbo and make more power for less cost and less work.
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Its no trouble at all, i have few REW blocks here and i am short on 13BT parts (irons mainly) , so its easier to put in REW.
I am considering it as challenge and just want to try something new....i have had 30 or so FC's, including 20B one and i have 3 FD's as well. This build is not about power. And third point : once done, when engine will be broken in, i can easily sell it to someone who will be in need of stock 13B-REW, fully dressed, tested, plug&play. |
Nice project, is like a throwback to me when i did this on my old red fc. I had alot of fun with the stock twins, big difference from mild 13bt to a stock 13brew with stock twin
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Yeah, i hope to have some fun with working twins and be able to turn it back into fully stock TII easily.
Today i found a position for radiator and intercooler, next step is make outlets and piping. Hopefully tomorrow. Fans are from rx8, radiator and IC are custom unfinished projects aquired with bunch of other parts, will make them work :) |
Ah, understood. I find 13BTs are easier to find near me, but if REWs are what you have available to you, I understand why it would be more practical. Curious to see what your impressions are of the stock twins. Anyways, good luck :)
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13BTs are long gone and most of them i tear down in last few years are cracked irons or broken coolant passages in them....already started ordering new irons
If i had good irons, i would have very like build FC block, but this was somewhat easier route for me. |
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Slowly but surely...
Intercooler outlets and piping done Radiator bottom pipe done Still have to make bleed and drain points and upper outlet on rad Fc front swaybar wont fit, but rx8 one will, just have to make 5cm or so thick spacers to move it little bit down |
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Finished welding radiator outlets, bleed, drain and some brackets on both rad and intercooler.
Modified some broken battery tray and it looks like it will fit regular size battery in oem location. |
Love this picture. So Euro cool.
https://cimg2.ibsrv.net/gimg/www.rx7...2682b2b441.jpg |
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Had to modify subframe for turbo control actuator clearance and decided to change broken spring in transmission too.
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Woah man, nice garage!
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Slowed down now, pressure test of IC/radiator showed some leaks which i had to fix.
As well made alu pipe bead tool. Still need to prepare some wiring before final install of engine (wiper and cruise control wires and gauges wiring) In meantime transmission fluid arrived, so i filled that up. Drilled stuck piston from clutch slave cylinder and rebuild it with new piston/seals. |
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Oil cooler lines done (hydraulic shop), oil cooler mounted in stock location.
Wired in Defi Advance ZD unit, utilising unused wires on FD harness (transmission sensors) Test fitted JDM downpipe (better clearance, different lenght), but decided to make own downpipe, since material was there already. Had downpipe flange laying already, just needed to be made flat after welding. Need to install ABS pump to see what space i have for EGT and o2 bungs, finish downpipe tomorrow. |
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Test fitted ABS bracket, modified heater return pipe and finished downpipe.
Welded narrowband and EGT bungs, chinese exhaust valve. Wideband bung tomorrow and then hopefully last fabrication task - swaybar spacers. Hopefully will start it up soon :D |
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Finished exhaust, wrapped and bolted in.
Managed to fit FD harness grommet into stock hole, its tight but looking good. Started to bolt in all brackets and stuff, would like to start it up during weekend |
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Bolted up few other things and drove the car out of shop today.
There is still 100+ items list to do, but it move by its own power, which is good :D |
Super resourceful build as usual hIGGI. Congrats on achieving a running 13BREW.
Wow, even kept the FC ABS system - that's dedication. |
FC ABS not connected yet, but it should be no problem.
There are more challenges to be done yet, one of them being converting FD3S PS pump to run with FC S4 speed sensing (3 hole) PS rack and FC PS computer.... And as well stock FC cruise control. |
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Today i made steel spacers (55mm height) for rx8 swaybar mounting, clearance to rim at full lock is tight, but its there.
Of course spacers could use some cosmetic adjustments, but for function, they are there :) Then i started measuring/preparing airbox connections to twins, will get it done tomorrow or day after. |
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FC airbox modification in progress :D
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Some recent progress
- wired in airpump (using FC A/C relay for that) - swapped relay in fuel resistor/relay box (needs to be NO, compared to NC which is originally in S4) - pulled replacement dash from storage and cleaned it up a bit - pulled old dash from car - installed headlights, headlight motors, FTPs, turn signals, fixed some wires - wired RPM signal to dash and Defi box - wired speed signal from PS computer to ECU and Defi box - replaced seals under brake master reservoir - installed windshield trim (except the top one) - installed wiper washer tank, brake ducts, wheel well liners and inner tow hooks - airbox still under works :D |
I like it! It's a cool kind of retro!
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this great info and pics, thank you!
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Recently been working on other stuff and cars, but here is some update :
Heater fan had faulty resistor, replaced. US S4 dashboard wiring using different connector than EU dashboard wirign, had to make jumper :D started on FC PS bracket modification to fit onto REW block (oem FC PS pulley setup, oem FC hoses to rack, just modification to FC bracket and installing front FC PS pulley on engine instead of original multirib) https://cimg6.ibsrv.net/gimg/www.rx7...9c1e5c24f.jpeg https://cimg8.ibsrv.net/gimg/www.rx7...9a8657232.jpeg https://cimg1.ibsrv.net/gimg/www.rx7...2a9b5e990.jpeg https://cimg2.ibsrv.net/gimg/www.rx7...16b24340d.jpeg https://cimg3.ibsrv.net/gimg/www.rx7...a7de8edd5d.jpg |
All your mods typically have good rationale and I'm sure these are no different, but a couple choices appear odd.
Dash: Why not just pull connector pins and reinstall into USDM connector? (or vice versa) Are the pins incompatible with the connector shell? PS: Very understandable that you'd go this route and retrofit FC PS pump onto REW block, but you're losing a great benefit of the FD - the serpentine belt system. Has anyone ever figured out how to adapt the FD PS pump to the FC computer ? I've never seen it done before. And you better paint that PS pulley before it rusts.:D You're almost there. |
Yes, pins are incompatible and i made jumper harness for simple reason. To keep both harnesses stock, so anyone else than me can refer it to factory manuals if ever needed.
I have never had issues with vbelt on PS pump, even when competitive drifting FC for some years, not worried about it in street car. Serpentine belt setup is of course retained for water pump and alternator, that stays FD. Pretty much like 20B setup. To keep serpentine and OEM FD pump, you would need to do lot more modifications which i was planning before, but this was much easier. Another easy route is custom making serpentine belt pulley for FC PS pump, which i might eventually do later on. PS pulley wont rust, its been sandblasted and silver zinc coated. Today i mounted it on car, filled up and tested. All good :) Actually mounted on airbox and took it for short test drive :) https://cimg2.ibsrv.net/gimg/www.rx7...43788f6792.jpg https://cimg4.ibsrv.net/gimg/www.rx7...19c2fdf821.jpg |
Incredible - looks like the FC/D is ready to roll. What ECU & boost control system are you using?
I now see many steel underhood brackets have been zinc plated as well. |
So far i am on stock FD ECU on stock FD engine harness, including stock boost solenoids.....
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Little updates, rewired fuel pump resistor/relay, but right now i have FD ecu error code 51, fuel pump relay.
With PowerFC car runs in boost, in stock ECU it goes into limp mode. Need to troubleshoot that fuel pump relay, maybe FD ecu is not liking FC relay/resistor :D |
Another little updates today.
Fixed wiring to fuel pump relay/resistor, stock ECU now does click relay prior start and no more error codes / limp mode. Tested idiot lights, all good. ABS works. Plugged in PowerFC for swich/sensor check, modified FC clutch switch to revert its operation. Next to do : Unplug diode between clutch and stop switch. Check if brake booster leak is not just the oring between booster and MC and dress up interior :) |
Got a datalogit? Can you post a log with sensors/switches enabled in monitor window?
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Originally Posted by arghx
(Post 12278465)
Got a datalogit? Can you post a log with sensors/switches enabled in monitor window?
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https://cimg2.ibsrv.net/gimg/www.rx7...bf9649894e.jpg
Interior work today, rear hatch, rear bins dress up. Then i made cruise control cable and shortened throttle cable. Have not been driving it to test it, will see if cruise works tomorrow once i finish up some interior bits. |
Cruise control works.
Had to put in back stock clutch switch and do change in wiring - FC ecu is grounding clutch switch, FD ecu is providing power to clutch switch. And diode between clutch switch and stop light switch needs to be removed. That very likely means kicking clutch will not turn cruise off, but i always use brake to turn cruise off and that works. |
https://cimg2.ibsrv.net/gimg/www.rx7...489d0508a4.jpg
https://cimg4.ibsrv.net/gimg/www.rx7...2b6c0c2503.jpg https://cimg7.ibsrv.net/gimg/www.rx7...c0c9851bf9.jpg https://cimg8.ibsrv.net/gimg/www.rx7...c256742f23.jpg Last few days progress : Front licence plate bracket Custom undertray bumper to radiator Oem oilpan undertray with very litte modifications fitted. Interior all dressed up For now, stock ECU for break-in, then it will get PowerFC Still need to do some small stuff, but its driveable as it is now, just need licence plates :) |
https://cimg6.ibsrv.net/gimg/www.rx7...bf69835111.jpg
https://cimg9.ibsrv.net/gimg/www.rx7...1813495300.jpg First 200km trip today, on JDM ECU (EUDM was acting up, maybe its faulty, some cold solder?, no issues with JDM today) Few small issues (passenger window switch, something rattling in drivers doors with window down) and annoying issue of 3rd gear grind. Other than that, no problems and car feels good. Still breaking in, but twins are really hard to keep from spooling :) Will switch to PowerFC soon and start logging. |
Finally got licence plates, still tweaking small bits.
After first 450km testdrive on hot day, i knew i will have to install second oil cooler. Prior installation, my oil temps went over 110C. All that still during break-in period. Couple days ago i installed it and yesterday took it to local meet, oil temps perfect. Coolant temps going to 100C, which i dont like, still need to work on that. Better ducting, low temp thermostat maybe will help.... Still on JDM tuned ECU, have not plugged in PowerFC yet. Tires on s5 FC wheels were rotted, installed some other wheels with better tires :) Next is transmission/diff swap. https://cimg8.ibsrv.net/gimg/www.rx7...84cde7299.jpeg https://cimg0.ibsrv.net/gimg/www.rx7...f5e80e7b4.jpeg https://cimg1.ibsrv.net/gimg/www.rx7...bd263776e6.jpg https://cimg2.ibsrv.net/gimg/www.rx7...4808ef89dd.jpg https://cimg3.ibsrv.net/gimg/www.rx7...4eec2f9766.jpg https://cimg4.ibsrv.net/gimg/www.rx7...7eecb990ab.jpg https://cimg5.ibsrv.net/gimg/www.rx7...2c60ccb3b4.jpg https://cimg8.ibsrv.net/gimg/www.rx7...089a641678.jpg https://cimg9.ibsrv.net/gimg/www.rx7...9c177a64e2.jpg https://cimg1.ibsrv.net/gimg/www.rx7...35051ab12e.jpg https://cimg2.ibsrv.net/gimg/www.rx7...0857e98ede.jpg |
I like the simplicity of your car, FC + REW = FUN^2. It also looks spectacularly clean! Also, in a sea of S5s and S5 retrofits, a clean S4 is quite refreshing. I made a decision a while back not to do any S5 updates to the body of my '87 and your car makes me think I made the right decision.
87 psi after two coolers? I'm very impressed and now I have solid frame of reference for doing the same thing. Great stuff. |
Nice build!! |
progress slowed up, working on FD which i just brought back from painter and is priority, but there is more planned or in progress for this FC :)
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modified RX8 5speed trans installed
6 puck sprung disc new front diff seal new problem with oil pressure (wont go over 4 bar once temp will reach 60 c and thermostats in oil coolers will open) |
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