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SPEED PERF6RMANC3 2.5L TopDog Engine - RS Build

18959 Views 122 Replies 27 Participants Last post by  mexrs
What a journey 馃槄馃槀 Lets not talk about the past!

My 2016 RS 15,000 miles now has the 2.5L engine from SP3 and if you want to learn about that engine, you can read about it here. Nishan, Jorge and everyone at the company has been great! 5 Stars. I was originally going to get the 2.3L engine but as I browsed the site I found the 2.5 and then I ended up upgrading to that. Also the folks at XDI have been great too.

What sucks is that I do not have E85 around here. It is not as easily accessible as in the United States so my power level will be lower that what i would otherwise be able to achieve. I am limited by pump gas 91 and WMI. So the engine may be considered overkill but oh well it runs and runs nicely.

Engine:
  • Compression 10:1
  • Sleeved 2L Block
  • Custom Mahle 2618 Pistons 89mm
  • Custom Manley I - BEAMS
  • SP63 625+ Custom 10mm Age Head Studs
  • ARP Main Studs
  • ACL Tri-Metal Rod Bearings
  • ACL Tri-Metal Main Bearings
  • Modified crank w/ Teardrop-shaped cavity
  • Keyed Crank, Timing Gear & Crank Pulley
  • Balance shaft delete Kit
  • Heat Treated In. & Ex. VVT
  • Custom BP285 Piper Cams with Manley 85lbs Valve Springs
  • O ringed cylinder head.

XDI EVO pump : At 200bar of pressure, the EVO pump flows 12% more than the XDI35 and 41% more at 240bar pressure.

XDI injectors : 50% more flow than OEM XDI-i010-50-4

Fuel Injector Technical Data:
  • 50% more flow than OEM
  • OEM 122lb/hr @ 100bar
  • 23g/sec at 100bar, 32.4g/sec at 200bar
  • 2000cc/min at 100bar, 2880cc/min at 200bar
  • 179lb/hr at 100bar, 253lb/hr at 200bar
  • Stable at 200bar even with OEM driver settings, completely linear flow

Quality Control:
  • Every injector flow tested on XDI proprietary DI test bench at
  • 0.8msec/20bar for idle stability
  • 10msec/100bar for static flow reference
  • 6msec/200bar for WOT performance
  • Every set high pressure matched within 1%
  • Every injector type validated for identical SOI and EOI via XDI proprietary injection rate measurement

Other Parts installed:
  • ETS filter and intake
  • ETS Intercooler and Charge pipes
  • Miltek Catless Downpipe Wrapped with Titanium wrap
  • NX2 Turbo with the PTP Turbo Blanket
  • Mountune 3" catback with no valve - V2X
  • Aquiamist Methanol kit
  • OMNI-Power 4 Bar sensor at the intercooler and intake manifold
  • Turbosmart twin port Wastegate [TS-0681-6142]
  • Turbosmart BOV but not vent to atm
  • Xtreme twindisk Clutch
  • LSD Quaife diff
  • Upgraded synchros and steel cage bearings
  • DSC contollor
  • Upr catch can, 100psi checkvalve
==========================================================================================

The install went smooth,

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I ran into the issue with the turbo manifold not mating well to the due to a bolt that was disturbing and found a thread about it and did the same and now it is happily seated. The thread is over here. Got some pictures added to it. Came out well.

I then installed the transmission and realized i did not see the centering guides on the block and also realized it was missing for the starter too so i had some fabricated. So i removed the transmission and sorted that out and installed the guides.

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Engine was then dropped in with PTU and transmission bolted to it. I also put on the PTP turbo blanket and wrapped the downpipe with titanium wrap from autozone. Now that the car runs and no weird noises like the Esslinger Engineering engine, it is noticeably cooler under the hood too. I was impressed with heat reduction and more impressed as that means less hot air gets sucked in to the engine.

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I then added the Wire harness and connected everything. Oh, first i wrapped the wire harness with tesla tape 51036. That was some awesome tape made for wire harnesses. Awesome stuff. then I bled the brakes and clutch using the pressure pump and used MOTUL RBF 700 fluid. Used the Orion Motor Tech Brake Pressure Bleeder, they also sell a cap with a 90 degree bend as it would otherwise not fit unless you remove wiper etc. It was super easy to use...

I then had to install the XDI pump and the issue here is the hard tube. I had updated another thread and added pictures their. It turned out great, just need to be patient. I used a new tube and practiced on the old one first lol. Here is the thread.

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While at it i also added the radium catch can drain so i don't have to remove the can every time like before as it is in a tight spot between the battery and the hpfp. Cleaned and oiled air filter, changed the radium fuel filter, added 21oz of AC refrigerant. Also all bolts I torqued to spec and marked them for visual check later if needed.

In February i will need to get a new set of Michelin PS4 tires. Mine have good thread but having been out of service so long and little use they have cracks in rubber but not sidewall. Either way, deserves new tires and i will feel safer when we start tuning.

Also ordered Mishimoto MMODP-12175BBK magnetic oil plug just because i felt like it 馃槀 and waiting for the dsc controller that a member here sold me and shipped it. Entered customs oops. Was hoping it does not but oh well, we will see what they tell me.

I put the 10-40 Motul Break in oil and had to have it imported as they do not sell it down here I searched and even emailed MOTUL in Mexico and no go. I ran the cams for around 25 minutes between 2,200 rpm to 3,000 rpm to break them in. Now i am in the process of doing the engine break in. Every builder has their way, speed performance have it 1500 miles before tuning and WOT so I will get the miles as fast as i can lol. The first 50 miles i guess are the most important so i did my best accelerating up the gears to 3500 rpm and then engine braking and repeating the process.

Runs good, and i cant wait to red line it when it is time just to hear the sound lol.
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that is where i left the radium catch can drain. Easy access.




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Just a pic of my xtreme clutch, looks so pretty lol. I am used to driving with it. I dont feel it is harsh engaging. I think it depends on the idle rpm.

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I had the bumper repainted, it is not yet polished. Not sure about the color match though. Will see once it is polished. Worst case, i have it redone. It is a pain though as everything on the front has to be removed like the mesh, fog light etc. The clips suck to remove and the plastic is fragile and i guess has limited time of removed and reinstalls.

I am amazed i was able to put it all back together after so many months with parts all around the house, garden and inside the car. I pretty much know it all with eyes shut lol. The shops owner and his assistant gave me a hand when needed. Some things definitely require more than one person to do safely. Like hoisting the engine back into the car. Coordinated work.
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Looks like a really nice build! (y) Is that your garage, or the shop's? Wish I had access to that lift! :love:
I wish lol, it's a friends shop. We take company vehicles to service with him. One of the cleanest and most equipped shops in town. All the good stuff is uppstairs, he buys tools like gadgets. Eventually they come in handy.

I bought this on Amazon

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I will need to do the ford misfire monitor neutral profile correction procedure. No ford dealer around and FORSCAN has added it apparently in the latest release.
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I got this today

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and installed the forscan on windows. has some nice features I will run. Like calibrate wipers.

I am not exactly sure what paid version does but for now I did the ford misfire monitor neutral profile correction procedure and saved my self a visit to the dealer.

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It asks you to rev to 3500 + like 3 times in total.

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I installed the dsc controller today



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You would think such a device would not make such an impact but let me tell you, the difference is very noticable and it is now so much more confortable.

perhaps more noticeable due to mexican roads not being so smooth.

Attachments

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I did the audio tweaking forscan that @RSt~n~peace recomended in another thread. The improvement is noticeable.

basically changed value from this

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to this

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What about that badass engine???
i am still on the breakin tune, another 200 Miles.

Also I was no longer in a hurry to put them quick since the tuners direct family member passed away and was told to wait and that it will be worth it.

So, waiting but drives great. For breakin i was told 1000 miles. Also looking at darton sleeves breakin process it is also 1,000 miles
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sorry guys not much to update, I had waited for about 7 weeks to hear from nishan at sp3 but about 2 werks ago... 9 weeks today. I remembered my lifetime tune with Adam. I did 3 revisions, car pulling great at 24psi in 3rd revission. I got some o2 sensor codes that explain some jerky activity between 1k and 2k.

then, last week retina issues that evolved to a retina dettachment and got vitrectomy 4 days ago. it was a macula~on detachment so 馃

So yea, car will just sit for now.
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Wow I was blueballed for months waiting to see video of this thing ripping. Please take your time, heal up.
On another note, why was nishan taking so long to tune the car??
I was told a close family member had passed away and to be patient and would get tuned once he sorted things out.

@mexrs , your RS is that fast that your eye popped out?!

I am kidding, praying for your "speedy" recovery.
I thought of that too 馃槅




I did have 2 codes come last week that go when cleared.

p2196 code show but no engine light. "o2 sensor signal biased / stuck rich bank 1 sensor 1" .... cleared it, went away.

p0172 system too rich (bank1) cleared it and its gone.

I was told to replace o2 sensor.. might order to have it ready
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Hope the eyes are all sorted for you sounded painful.

How's the tuning coming along
The operation was on April 12 and got retina attached and silicon oil fill lol. I will have it sucked out in September or October the latest.

I have resumen tuning and never changed the o2 sensor although I have it. I believe it was tube related with earlier tuner. it would jerk too much between 1 and 2k rpm and guessing it was fue.related and triggered the code I was getting.

Ryan and pdtuning has tuned so.far, no more codes. runs very smooth 1k to 2k rpm and above. My limitation is 91 oct.

Once we are done on that, we do WMI tune. I also thought of tuning for racegas concentrate additive. RACE GAS | Racing Fuel Concentrate or VPracing brand. If bump to 96oct that would yield nice power.

ALSO got covid 2 weeks ago. I had mainly fever a few days and back to normal. I got worried since I had no vaccine but then all my vaccinated friends got sick too and some worst off. looks like omicron gets everyone who comes in contact with it.

Have not posted Since still tuning but I am happy with it so.far
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Changed oil and installed this while at it. should be doing wmi tune very soon

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Video of your Baby Beast when able...Thanks
Headed to Europe and Egypt, back 20th to resume tuning.

I have been thinking of putting a sport cat in.place of catless downpipe.

is a sport cat just as loud? anyone tested
I can vouch for going sports cat from OEM. It鈥檚 louder than the OEM as it flows more air but wouldn鈥檛 think it would be as loud as going catless
sound was perfect untill I ditched oem cat back and put the mountune catback when I had the esslinger crap engine

I only did it at the time because Alex at Stratified told me it was restricting lol. I thought it was odd considering I was on 91oct.
Ryan emailed and we will do a live sesi贸n to finish tuning the 91 oct tune when I return. During the booked time he will be waiting on my logs,to send back and he sends revissions as needed. I just take laptop with me and share wifi from phone.

whp figure I get when I am done with wmi tune. dyno is about 3hr away and at 6000 ft. I'm at 200ish feet.
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as long as your tuning is at where you are normally driving....all good.
i'm glad everything is working out good this time.
i can't wait to do a 2.3 build and re-tune.
I know I will get lower reading at that altitude... but don't they always give a corrected reading for sea level?
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i'm not sure about that? they may need to provide you with 2 separate tunes...6k ft tune and sea-level tune. it's not an absolute necessity...but at your level build...it would make sense.

with my tuner...i just asked him for an elevation tune while i was at 5500 ft. he adjusted my current tune on file and sent me the revision (no need for data log run at elevation). when i left that area...i simply uploaded the sea-level tune again.
awesome, good to know馃檭
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I haven't updated in a while but all is good. The 91 oct tune has been completed a while back and run just under 25psi with the nx2 and 2.5L engine with piper cams and all the bolt ons. it runs flawlessly and smooth in all rev range.

I then had the follow up surgery on the eye that was pending and then we started the wmi tune but since the kit was sitting for so long since I bought it, one of the sensor cables had a glitch, and the filter was clogged so some downtime while parts arrived .

I did a log on WMI tune a week ago and was at 29psi. 馃コ the limit on the sensors are 29psi so I am now waiting on 2 new 4 bar sensors from Omni Power.

we expect around mid 30's PSI with wmi

I am using the aquAmist 1.2+mm jet which is rated at 720cc/min flow
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The 4 bar sensors arrived, the wmi tune revission for 4 bar sensors is ready to run BUT

Yesterday as I drove fast on a Mexican public highway I hit a pothole.... today as I was washing the car I found tire damage so now I wait for tire that arrives on Wednesday.

I am considering 18inch wheels

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