Rallye Inlet fitting problems --> need ideas
 

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.



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?

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

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

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 :) :)

http://www.saxperience.com/forum/sho...d.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

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.

so i've been working on the rallye throttle body:


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?

try sparco tom for the cable :)

do these make much difference?

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

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!!!

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:


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

this is something i made to fit the MAP sensor

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.

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?

tried it but it doesnt help...

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