Rallye Inlet fitting problems --> need ideas

[kistigun]

Finally got my Rallye inlet(with throtle body and sensors) yesterday:panic: i've been cleaning it today and i want to fit it this weekend.
http://i39.tinypic.com/2dhhbao.jpg
http://i44.tinypic.com/n3wz6e.jpg

I've been reading a lot about fitting these but still got some questions. I want to fit this on a cammed TU3JP engine(early phase saxo furio) got the original really inlet gaskets and the spacing is the same so fitting it on the head aint going to be a problem. I want to avoid drilling holes in it for fitting sesnor so this is my plan:

- Can i use the ICV, temp sensor and TPS from the rallye inlet(think it's plug and play except for the tps were i have to switch some wires)
- There are 3 brass niples one the inlet, 2 small ones and one big one. I think one of the small ones is for the servo brake hose? I want to use the other one for connecting a MAP sensor, is this possible?. What does the big one do?
-The are 2 nipples under the ICV, i just need to close these?
-Can i also use a normal throttle cable?

Can anyone help me with these questions?

[samueljonburgess]

o cant use the normal throttle cable mate :).... i didnt know you could fit these on a furio.... :(

[kistigun]

as long as the port spacing is like this 00--00 and not like this 0-0-0-0 they'll fit

[samueljonburgess]

damn :( may lok into it then... as the vtr one i have atm is pissin me off

but ye u need the throttle cable off the rallye i think mate, all the sensors i dont really know about


good luck :) let me know how it is when its done :) :)

[dorsetsaxo]

http://www.saxperience.com/forum/showthread.php?t=296686

page two mate

[kistigun]

http://www.saxperience.com/forum/showthread.php?t=296686

page two mate

thanks mate, gooed guide but first i would like to use the rallye TB and avoid drilling holes in the inlet. if that aint going to work i can try your guide

[blackie_2k5]

right mate, you NEED a 106 throttle cable, the big run off (mipple as youve named it) near the head side of the main is for your brake servo, the two near the back iirc one you fit a vacuum hose to, one i blanked. the to inlets/outlets(nipples) on rallye tb (the black ones in the second pic above the tb inlet) need blanking or theyll draw in air. and in all fairness these can be an arse to get running right so id really consider drilling the mani and fitting the furio icv, its not hard and gives you piece of mind.

[kistigun]

so i've been working on the rallye throttle body:
http://i44.tinypic.com/7318no.jpg
http://i42.tinypic.com/1zpipv5.jpg
I've used the TPS from the VTR TB so i don't need to rewire and use the rallye TPS, also adjusted the manifold a litte bit so the VTR MAP sensor would fit. I'm going to try and use the rallye ICV(so i don't need to drill a hole in the rallye mani).

I still can't find a rallye or saxo diesel throtle cable, anyone got a partnumber?

[samueljonburgess]

try sparco tom for the cable :)

[Pidge]

do these make much difference?

[Aly]

To cure the throttle cable issue, you can use a one off a 1.5 diesel mate.

[kistigun]

well fitted it today, used original throttle cable(was long enough) it still idles a little bit high but the ecu has to learn. Also the raceland airbox needs to be adjusted. did a little test run, it sounded great!!!

[samueljonburgess]

bolted on and ran fine first time?? :)

[kistigun]

bolted on and ran fine first time?? :)

yes it ran the first time, but i wont idle propperly... it idles at 2.5k... anyone ideas? here are some pics how i fitted it:
http://img260.imageshack.us/img260/9389/dsc03543v.jpg
http://img638.imageshack.us/img638/4549/dsc03544m.jpg
I used the rallye ICV, maby if i switch this for the VTR ICV it idles better.I used the brass niples at the back for the gas tank breather pipe and the MAP sensor
http://img138.imageshack.us/img138/1690/dsc03545b.jpg
this is something i made to fit the MAP sensor
http://img201.imageshack.us/img201/8155/dsc03546x.jpg

[samueljonburgess]

looks smart mate.... probly the icv iam having trouble with geetin my vtr inlet to idle properly.... have u tried moving the cable so the butterfly is closed??

[kistigun]

looks smart mate.... probly the icv iam having trouble with geetin my vtr inlet to idle properly.... have u tried moving the cable so the butterfly is closed??

The butterfly is closed, so i think the icv is causing the problem. The vtr icv doesn't fit so i'm going to look for an other solution without drilling in the inlet.

[tweeqd]

the pipe on the map sensor is way too long, by the time the sensor reads the vacumn change it will be different in the manifold and will cause all sort of problems

[kistigun]

the pipe on the map sensor is way too long, by the time the sensor reads the vacumn change it will be different in the manifold and will cause all sort of problems

ok thanks, if i connect it directly to one of the brass niples at the back it would be better?

[kistigun]

tried it but it doesnt help...

[vtr_chris90]

tbh mate i think you may need to drill the inlet, i know you dont want to, but i think you may be best using the vtr icv like alot of people do on here

but before you do that, have you got access to diagnostics?
i would say get some diagostics done, and have a look to see what it reads the throttle to be at
because what im thinking is, because youve made a plate to fit the origional tps sensor, the sensor only needs to be like 1mm out of place for it to give the wrong reading to the ecu, so if it is postioned wrong it will be telling the ecu the throttle is open when its not and it will then draw air in from the next nearest place which is icv which is why it may be idling very high
so could be worth getting a readng to see what the inlet sensors are reading
failing that then i thik you may have to drill the inlet and fit vtr icv like others on here have as hey have had no probbs with idling. and also drill a hole for map sensor

hope that helps

[dorsetsaxo]

but youll need to take it all off to drill as you dont want a metal filling goinig in to head

[axsaxoman]

first check voltage at TPS when at idle --must be less than 0.65v.
and rpm of engine must be less than 1050rpm ,or the idle control system will not work ,as the ecu will think you are in a very light trottle postion .
If throttle is shut and so is ICV and it wont, run below 1050 --then you have an air leak .
length of tubing on map sensor will ahve no bearing on value .
.
If you can mesure manifold pressure --at idle it should be steady --if not then your cam is too wild ,and you will never get a good idle at sensible rpm .
this is why you must fit t/bodies when you have wild cams --so you do not get charge robboing from 1 cylinder to another which will cause map vlaue to be irattic --causing poor or no idle .

so theres a start for you

[kistigun]

ok thanks for al the tips, going to measure the tps voltage and the inlet presure tomorow at work.

when i put it in gear and play a little bit with the clutch te rpm goes down to 1k and stay there when i put it back in neutral.

[samueljonburgess]

i had the same trouble mate its probs the icv.... so mite have to drill a hole to get it to tick over properly.... does it only do it until its warm??

[kistigun]

i had the same trouble mate its probs the icv.... so mite have to drill a hole to get it to tick over properly.... does it only do it until its warm??

no it does it all the time, hot and cold. thing i'm going to fit the vtr mani back on and drill holes in the rallye inlet for the map & icv.

[samueljonburgess]

ye probly the best move :) seems to work for people after that is done, make a good noise tho? :)

[kistigun]

ye probly the best move :) seems to work for people after that is done, make a good noise tho? :)

yeah the noise is awsome!!!

[kistigun]

A few weeks ago i pulled the rallye inlet out of the closet to adjust it and give it an other go;

http://img51.imageshack.us/img51/9364/dsc0037fk.jpg
http://img802.imageshack.us/img802/2977/dsc0036f.jpg
http://img20.imageshack.us/img20/3842/dsc0035ox.jpg

I've drilled a hole in the mani for the map sensor & the ICV and i adjusted a vtr TB so it would fit the rallye inlet. I fitted the inlet last monday, started the car and it idled fine arround 1000 rpm. So i took it for a ride, while driving i noticed that the throttle was very sticky while shifting. I've checked the throttle cable and there was no problem with it.

What else could cause this? air leaks? or is there something wrong with the set up?

[tom_lloyd_4]

mate dont supose you fancy selling me the rallye tb ;)

[stevo1600]

what you mean sticky?

as in its taking long for the tb to shut or hard to open with foot?

or from the enginebay side, hard to open with your hand?

i would imagine it either needs oiling or your throttle cables had it mate.

im suffering with one problem with my rallye inlet, when i give the car some, the revs take a fair amount of time to come down. possible air leak?

[blackie_2k5]

dogey icv or air leak mate

id say air leak, i had the same but it still idled high first time round, then i blocked the hole and it was spot on

[kistigun]

ok i'll think there has to be an airleak somewhere because the icv is from the old inlet and was working fine. Will check it for holes and try it for one last time. if it's not working i'll willing to sell this