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LH2.2 Tuning For Non-Volvo Installation / X1/9 Dallara + K24 Swap

Congrats, looks like fun!

Many thanks - it certainly is. Will be awesome once the kinks are worked out & I get it dyno-tuned

Welded the bias bar sleeve to the brake pedal

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cut a slot for the bias bar to recess in to

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Worked on the MC mount plate mock up

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Need to add ridge to make plate more rigid

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1.25" offset will be good

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3.25" height, 4.5" wide

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Will add webbing to support mount plate

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clutch pedal needs to sit approx 1/4" out for stop to sit on buffer/adjuster

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Bushing needs to be 6.375"

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Have to cut this out more where mrker line is to allow pedal to come forward / up

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Bought some 1.25" and 3" flat bar stock to work with. Then I remembered I had a spare eBrake pulley cover from the parts car, so I cut that down. Alrady has a nice rolled edge for rigidity

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Bolts will be welded in place - reverse position of what is shown here - no practical way to access the bolt heads once the webbing is in

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Welded the brake pivot extension

"L" section under the forward edge

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rear extension

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With V70 clutch master in place

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Have to cut back the bracketry directly under the bias bar - it is just touching on the midsection plate at full height

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Wrapping up the pedal box welding. Required assembly/diassembly multiple times to check fit, clearances, adjustments, tweaking of clearance areas around the Bias Bar, MC fitment area fettling after welding, etc.,

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bent pedal arm again to get 4" offset back. Can't be wider, just no room under there

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Brake lines from MC's have to go the this junction. Have to make those next. 3/-24 at MC to M10x1.25 (or is it 1.00 pitch, I forgot) at junction

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Hose routing

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or

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I can imagine that took a lot of tweaking for sure, but final product looks good!

Thank you. Happy with the overall progress.

I made the brake lines today. The stock MC had two front outlets, so I needed to split the front output to two lines. I repurposed one of the stock junction boxes.

Stock layout that I am replacing:

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Cross-drilled the channels & tapped with 1/8 NPT to block it off

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Blocked off one of the outlets

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Lines done

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Rear MC goes to the single junction. MC ends are 3/8-24, junction end is M10x1.25

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Bracket will retain the two junctions

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Junction bracket done

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Got a 50? PND gear off an RSX. Not going to be happy with 25? limit of the RBB / TSX gear

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Added a limiter pin, reduces max advance to 40?, safe limit for the 2.4 vs the 2.0

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Set crank to TDC

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Cams set

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tensioner cover - removed and tensioner pinned to prevent chain extension

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Cam caps off

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Cam out, gear swapped, cam in. make sure my chain markers aligned

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rotate couple revolutions, check timing again

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All back together

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also added iVTEC emblem to the trunk, and put on my new plates

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Worked on a new gauge pod. Not going to put a stereo in the upper dash.

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M4 rivnuts

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vinyl cover

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Oil Temp, WBO2, 5bar Volvo gauge used for fuel pressure

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Finshed the wiring of the extra gauges

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Just need black screws

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SpeedoHealer to try & get the Honda trans to talk to the Fiat Speedo :D

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Had grind back the shifter base to clear the frame when shifting into 5th

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After that, put the console back together for now

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Figuring out the gauge layout with the Marshall Speedo & Tach. Has to fit 15" x 4.125", difficult to get the 4 52mm in that space

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in the low 20's today, but sunny & dry, so I took it out to make sure the new cam gear is good.

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Still have to do the Dallara stripes - like this:

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Got it on a lift after that, no leaks I can see

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This is how I had it mocked up in cardboard - not going to work with my steering wheel

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holesawed out the gauge holes, with the 52mm gauges reversed

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Checking the gauge clearance in the aperture. not sure how I'm going to finish the surface, probably just clear coat. Still have to figure out all the idiot light arrangements

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and so...

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Wirign goes slow.

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GPS sender for the speedo in on top of dash, not going to bother me there

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finished the cluster install, nice to have a working speedo & accurate tach

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CEIKA revised offset parts came, so I put the front brakes in

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Figuring out the remote adjuster for the brake bias bar. Their instructions are confusing. They say to remove the jamb nut, but without it the adjuster will just undo if trying to go CCW, so obviouly the jamb nut has to be kept in place.

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Finished the Dual Master setup & installed in car. Pedal has never felt so good.

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Some bending and repositioning of the stock hard lines later...

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tight fit around the heater box & vacuum valve

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Had to make a new adaptor line for the Volvo V70 clutch master - there was no room to attach the hard line to the original one I made

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Bias bar adjuster was a PITA to attach

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Had to drop it & swap out the clutch hose for EPDM

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Used a section of C30 expansion tank hose

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Finished up the remote adjuster for the balance bar.

Made a bracket for the adjuster knob, and a reinforcing plate for the backside of the dash. Threaded the knob plate for M4x.75 screws

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making a retainer for stereo in glovebox

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finally washed the car for the first time since last fall

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interior mostly back together

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replaced the ambient temp gauge I had put in with one that is easier to see in sunlight

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Been driving it whenever the weather is good (days above freezing and clear skies) - got over 220 miles on it now. Much teething issues - still don't have working IACV which is causing nasty random throttle tip-in jerkiness, and the AC lines at the compressor need to be re-worked o get them off rubbing the engine cover hinge. Smelling burnt coolant also. Did the CO2 sniffer test at the reservoir which did not indicate any exhaust gasses in the system, but it's defintely smoking on first start. I'll have to do a leak-down test next.

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extended the fittings here, but this is too ungainly and the extended leverage loosened the high side the first time I took it to work.

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Got some new variations on compressor fittings to experiment with a more 'relaxed' fit for the lines

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Also rewired the center console to use the early style rocker switches & panel. Finished up the keyless entry & stereo install in the glovebox also

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Not happy with the AWD on the C30 - doesn't engage quickly enough or agressively enough. I'm putting a Quaife 11J in the rear diff - had to be welded to the ring gear

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after that was machined off the original diff

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Besides that, I'm switching to a VW Haldex module to use in concert with a Van Der Veer controller that can be adjusted and monitored using a phone app. The current setup cannot even be checked from VIDA since the system is not integrated into the BCM/CEM.

I also spent some time yesterday welding a new flange for the external WG I'm using as a exhasut dump valve (set to 10psi) - the original was severely deformed when I welded it to my sectioned exhaust piping. You can also see where it was hitting the frame rail on haevy bumps - now it's offset downward another inch or so for better clearance

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Remade the low side(#10) hose. 135? fitting at compressor, #12 MOR, welded to #10 beadlock hose barb. Nice & relaxed fit now.

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Made a new high side elbow off the compressor fitting - with that I have a good fit

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Drww it down, but wouldn't hold vacuum for an hour - had to recrimp the #8 hose I made at the condenser, that has been a problematic one.

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Used the #6 die to make it tighter crimp - no more leak

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It's pretty cold out, however it still gave duct temps about 30? below ambient, so I think its a success

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Worked on the Volvo rear diff today. Getting frustrated with the Fiat - can't figure out the idle surge fixed. AC system is done finally, thank goodness.

Note: 999-7160 special tool required to remove rear axles without damage to casing

Installed the carrier bearings 32008X/Q x2

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about an hour or so to get the mating surfaces free of anaerobic sealant remains

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preload shim on right side, left side gets the backlash adjuster

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right side cup & preload shim going in

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diff in, cover sealed with anaerobic sealant, torqued to 18ft/lb

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new axle seals 8653928 x2

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preload set (5.25 turns), then used old seal to install new seals

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Had to drill & tap the remains of the rear CV, it was jammed in the pinion flange

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Next I can remove the flange, and replace the Haldex filter & rebuild the pump.

On the Fiat, still trying to resolve the idle issues. Found the IACV connector I used is numbered backwards compared to factory diagrams

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factory diagram

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Tried flipping the ground & signal wires to what should be, and then the engine won't rev, TPS does not register. The two circuits are not directly related in terms of wiring, so I don't know where to go with this. I did order a new OEM IACV, as the aftermarket one is definitely non-functional.

I modified one of the dead ones to make a manual adjuster - it works but requires one setting for startup, and another for driving, ot practical for daily driving

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