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SPEED PERF6RMANC3 2.5L TopDog Engine - RS Build

18923 Views 122 Replies 27 Participants Last post by  mexrs
10
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,

Gas Welding Event Engineering Machine


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.

Water Road surface Fluid Automotive tire Asphalt
Building Vehicle Engineering Gas Motor vehicle



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.

Motor vehicle Automotive tire Hood Automotive lighting Vehicle


Automotive tire Motor vehicle Vehicle Auto part Gas
Automotive tire Motor vehicle Wood Headgear Automotive wheel system


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.

Automotive fuel system Automotive tire Motor vehicle Vehicle Automotive design
Tire Wheel Vehicle Automotive tire Motor vehicle
Automotive tire Hood Motor vehicle Automotive design Automotive fuel system

Vehicle Automotive tire Tire Automotive fuel system Motor vehicle


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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please create a new thread :)
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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
  • Boche 3.5 Bar sensor at the intercooler.
  • 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 on the way
==========================================================================================

The install went smooth,

View attachment 357850

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.

View attachment 357852 View attachment 357853


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.

View attachment 357854

View attachment 357855 View attachment 357856

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.

View attachment 357860 View attachment 357861 View attachment 357859
View attachment 357858

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.
Really cool. can someone explain what the balance shaft delete does? I thought you would need that?
The balance shaft system consists of a gear driven unit with a pair of opposite rotating shafts which balance out and reduce the engine NVH.
Removing the unit allows the engine to rev out freely but does increase the engine NVH.
There have been cases reported where these have failed and when doing so cause catastrophic engine failure, so if planning increased rpms and torque I would remove it, as I have done on mine
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I installed this, it seems to make it less noise. Need to step in it to confirm. sucks that I did not record db before. But it seems to have deeper tone now.


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Added this to my wmi system close to jet T. because my fast acting valve was far from them.


Font Screenshot Parallel Number Rectangle


This was a ***** to remove. changed it due to codes a while ago that mentioned the sensor and left me stranded on highway but ofcourse it might not have been an issue with it but changef it regardless as it has seen it's share of oil blowby from earlier engine.


Tune wise, still not done as we have the issue with xdi pump running away with psi higher than demanden so it can go to 3500psi when demanden is like 2000psi and ecu cuts power.

apparently other RS owners with same issue with xdi but not on mustang that has different ecu. So tuner reached out to cobb and xdi.
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apparently other RS owners with same issue with xdi but not on mustang that has different ecu. So tuner reached out to cobb and xdi.
if you can't get it sorted...i hear great things about the bosch HPFP. much cheaper and direct bolt-on.
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if you can't get it sorted...i hear great things about the bosch HPFP. much cheaper and direct bolt-on.
View attachment 364726
That sure looks like a Supra HPFP aka b58 tu. The only mods are the electrical connector and fuel line quick connect. I might be tempted to test it out. It would make a relatively inexpensive upgrade. Definitely worth taking a look into.
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The Bosch HPFP pump works a treat.
I haven't ran out of fuel pressure and it feeds 4x GDI injectors and 4x 1000cc AUX injectors.
A big bonus is the car will run so you can at least get it to the tuners to map it all in properly,
as I think the XDi pump leaves you dead in the water.

Well worth it :)

AND its BOSCH with reliability which the XDi hasn't got close to yet.

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I'm done spending 馃ぃ
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happy you did. Hope you finally get to enjoy your built RS! It looks like it rips.







I'm done spending 馃ぃ
Ha ha, good one!
The Bosch HPFP pump works a treat.
I haven't ran out of fuel pressure and it feeds 4x GDI injectors and 4x 1000cc AUX injectors.
A big bonus is the car will run so you can at least get it to the tuners to map it all in properly,
as I think the XDi pump leaves you dead in the water.

Well worth it :)

AND its BOSCH with reliability which the XDi hasn't got close to yet.

Sorry for thread jack... But can anyone speak to the actual drop-in nature of the Bosch HPFP? I purchased one from MSD at the link included here, and took it to my local shop, as I didn't trust myself on the install... They called to let me know the hard line would need modified to make the Bosch HPFP work, and they didn't feel comfortable trying to manipulate the hard line.

Does my shop not know what they're doing, or is there a need to purchase a modified hard line to make the Bosch HPFP work??
Sorry for thread jack... But can anyone speak to the actual drop-in nature of the Bosch HPFP? I purchased one from MSD at the link included here, and took it to my local shop, as I didn't trust myself on the install... They called to let me know the hard line would need modified to make the Bosch HPFP work, and they didn't feel comfortable trying to manipulate the hard line.

Does my shop not know what they're doing, or is there a need to purchase a modified hard line to make the Bosch HPFP work??
It鈥檚 a direct fit, I bought mine from devil and it was fitted by Hendy performance the only mod required should be to cut off the 2 pin plug and wire in the plug that comes with the hpfp
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Sorry for thread jack... But can anyone speak to the actual drop-in nature of the Bosch HPFP? I purchased one from MSD at the link included here, and took it to my local shop, as I didn't trust myself on the install... They called to let me know the hard line would need modified to make the Bosch HPFP work, and they didn't feel comfortable trying to manipulate the hard line.

Does my shop not know what they're doing, or is there a need to purchase a modified hard line to make the Bosch HPFP work??
on the xdi you need to bend slightly and could be done with the right tools. I got mine to fit fine. xdi also have the option of selling you one pre bent. either way, a new line should be used
on the xdi you need to bend slightly and could be done with the right tools. I got mine to fit fine. xdi also have the option of selling you one pre bent. either way, a new line should be used
Bending Not required for the Bosch hpfp
Bending Not required for the Bosch hpfp

xdi said the same since minor bendiga is considered drop in lol. @jhelwege bought boch unit and has same issue
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Not had it on mine
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Not had it on mine
Maybe Hendy performance bent It slightly and didn't mention?
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I鈥檒l ask them
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I鈥檒l ask them
Thanks for the response, and definitely interested to hear what they say... I'm thinking I'll try to replace it myself here soon... Not sure why the shop had an issue, but might as well try to see for myself.
Sorry for thread jack... But can anyone speak to the actual drop-in nature of the Bosch HPFP? I purchased one from MSD at the link included here, and took it to my local shop, as I didn't trust myself on the install... They called to let me know the hard line would need modified to make the Bosch HPFP work, and they didn't feel comfortable trying to manipulate the hard line.

Does my shop not know what they're doing, or is there a need to purchase a modified hard line to make the Bosch HPFP work??
Can you show a picture of the item and the issue. You know a picture and a thousand words etc lol
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