I saw that mentioned in another thread somewhere but I've never seen a keypad in my glovebox. Someone mentioned that its only certain models and certain regions that have that. Will double check tomorrow though

You will have a keypad in the glovebox Chris, it's stuck to the back wall of the glovebox and is about the 30mm x 60mm from memory.


This all sounds very strange, other than the fact you mentioned the battery had been off the car for a couple of weeks? They tend to go flat in a week or so when connected to the car, perhaps your battery has seen better days?

Battery is brand new (replaced by Toyota under warranty about 2 weeks before the engine came out) so I'm pretty sure its fine. I'll take a look at the keypad tomorrow, though not sure what I can actually do with it... will have a look at the owners manual and see what it says.

To be honest I'm leaning towards thinking we've just messed up some ground connection somehow. Seems odd that this happens right after we have disconnected and reconnected everything in the engine bay eh. Is there anything else other than the 2 ground cables that go from the underneath of the engine to the chassis (near the wheel arches on each side) that I can check? Someone mentioned the ground for the starter motor but they also said its pretty unlikely we could have messed that up (they obviously haven't met me!)

This is a low battery fault. My car does this when the battery gets very low. A buzzer in the boot starts going off until it goes pan flat. It's a high frequency buzz not a slow pulse.
These cars drain the battery fast if left connected and unlocked. I get 3-5 days out of mine sat in workshop normally.
Put a multimeter across battery.

There is an earth strap which goes under one of the starter mounting bolts from memory?? Though I don't think this is the issue..


That would not cause the dash to do funny things in my opinion. Has the bonnet switch for the alarm been disturbed? try disconnecting it and see what happens.


Surely the guy who's built your engine can sort this out? It's gonna be something silly!!

You were definitely right about it being something silly haha there were two issues, both equally stupid.

Firstly, the Start/Stop button wasn't starting the car because it wasn't connected to anything :lol: We removed that button and the trim around it when we installed the hydraulic handbrake, and at some point we put it back but didn't reconnect all the electrical cables to the back of it as we were just seeing if it all fit properly. Apparently then we all completely forgot about it...

Second issue was that there was no fuel in the tank. Took us longer than I'd like to admit to realise this.

As for Ricky (the guy who built the engine), I gave him a ring before we realised what the problem was and he actually happened to be staying at a hotel just round the corner from me (which is a weird coincidence, as he lives about 200 miles away from me). He was kind enough to come round and give us a hand sorting everything out. We had an issue with the serpentine belt jumping off the crank pulley the first few times we fired it up and he sorted that out and stuck around until we had got everything to a good state.

So yeah as it stands now, the engine is back in, all seems to be running ok, just need to put it through a few more heat cycles and then take it to Fensport to be mapped for more boost (which is already booked in for early Feb)

Nice one Chris, hope it all goes well for you from now on. look forward to some dyno graphs!!

just watched your video. very cool seeing things progress on the forum, then getting a recap on your YouTube channel!

Changed the oil after running it through a few heat cycles over the last couple of days as recommended, then took it for a test drive today... and all seems good :) haven't thrashed it yet but so far so good. Looking forward to getting it mapped next week

Nice, let s wait the reprog ;)

Did you get it mapped and what were the results?
How are you enjoying it so far?

The turbo bearing died when Fensport were mapping it... so had to wait a bit for a new turbo (went stage 4 instead of stage 3 this time as got a good deal on a stage 4 one).

Once that was sorted, they noticed oil building up in one of the cylinders. So I took it back to Ricky as I assumed it must be something to do with the engine rebuild, but we found it looks like the oil is coming from the intake manifold. Seems like the catch can Fensport installed as part of the original turbo installation is doing absolutely nothing (as it was bone dry and the intake manifold was covered in oil). Can even see oil stains on the inlet ports where it has run down into the cylinders.

So yeah... not having much luck so far lol Ricky has got the car this week to modify the breather system to try get this catch can to actually do its job, and also do another leakdown n compression test just to be sure its nothing internal. Then hopefully all being well, I'll get it back at the end of this week or early next week and can take it back to Fensport to get the final map done.

even if the leak down isn't the greatest, i wouldn't worry too much. the top rings still need to seat before that clears up.

What's the difference between stage 3 and 4? Where did U bought it, how much?

Rings fully bed-in within 10 minutes. Partially bed just rotating the engine by hand.
Leakdown should be around 3% on a fresh Snap-on leakdown tester if the bores are fresh on those CP's and providing the valves are sealed perfectly.

Odd that it's breathing that heavy as the stock setup just sucks into the intake manifold via a PCV. Hopefully the leakdown will tell you one way or the other. What condition were the bores like? Did they have a good hone for the new rings to bed into?

How did the leakdown test go? That would be a cool video for your engine builder to do for those that don't know what a leakdown test is

Any updates?

The oil issue was definitely because of oil being passed back into the inlet manifold through the PCV system instead of getting caught by the catch can. Engine builder quickly spotted and rectified this by changing the way the catch can hoses are set up (free of charge, even though it wasn't him that installed it originally - so thanks for that Ricky!).

Once that was all sorted it went back to Fensport for the final map. They did encounter some fuelling issues at very high RPM but got that sorted in the end and rang me yesterday to say it is all done. Apparently they've got it running 1.2 bar of boost (17 psi) through most of the rev range and said it pulls really well.

Picking it up on Tuesday and will be taking it to a rolling road day that the gt86 FB group has organised on the 27th so will see what power its making exactly. I'll update this thread with impressions of driving it once I get it back

http://s10.postimg.org/tfj7mw07t/20160327_174252.jpg

Got it on the dyno last weekend and as you can see peak power at the flywheel was 335 bhp and 275 lbs ft of torque, which is quite a bit less than we were expecting.

Considering someone else with the stage 3 turbo running 0.8 bar of boost got 325 bhp (not sure if that was on a different dyno though) it seems odd that stage 4 turbo running 1.2 bar of boost would only be 10 bhp more. The stage 3 run was on stock compression ratio whereas I'm on 10:1, but surely the extra boost should easily make up for that and then some. Of course this is only peak power, its possible mine is making more power elsewhere in the rev range but I don't have a graph of the stage 3 to compare to.

Fensport suggested that perhaps the tyres were slipping on the dyno as this seems like a very low figure to them for the setup I'm running. We did have issues with the tyres spinning at first but the guys running the dyno strapped the rear subframe down and said they were happy that the tyres weren't spinning after that. Fensport did also say when they mapped it that they could push it and probably get another 20 bhp out of it but that they'd rather keep things safe especially as I'm going to be bouncing it off the limiter at drift days every now and then (thrashed it at a drift event just 2 days ago and it survived).

Regardless of the numbers, I'm happy as it pulls really well now - definitely noticeably faster than it was before with 0.8 bar on the stock engine. Everyone that I took out for a spin at the GT86 dyno day was shocked at how fast it was so I guess that's a good sign lol spins the wheels up easily as well and that's what I wanted.

Next job is getting an extra set of calipers mounted to the rear so we can get the hydraulic handbrake working, and also fitting a 1.5 way LSD. Fun times :)

That's awesome man! Thanks for the post the suspense was killin me waiting to see how it did. I did also expect it to do better on stage 4 than that though. Let us know what you find out!


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something doesn't seem right. i made 300whp on regular pump gas with a base avo kit around 11psi. 400whp at 18psi on e85. even with the compression drop, 17psi with the slightly larger avo turbo i feel should make way better than it did. either way, glad you got it all sorted out and running right again. numbers don't really mean a lot anyway, its how it feels :thumbsup:

Yeah that's what we were saying, people seem to make this much with way less boost and on the lower stage turbo kits, so it does seem a bit odd. Fensport also said when they mapped it and logged everything they didn't see any kind of drop off in torque towards the top end like there is on the dyno graph.

So I dunno, I could probably get better numbers if I went on a different dyno and put better tyres on and had some more weight over the rear etc etc, but I'm not bothered about dyno numbers enough to do that. It drives great now so its all good

That's all that matters is the you are happy with how the car drives. Numbers are all that matter to some people.


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US dyno vs the world.
Their dynos read a lot higher

0.8 bar @ 12.5:1
You are running 11.6 PSI of boost at an altitude of 0 feet. Your motor's static compression is 12.5 :1. At this boost level and altitude your effective compression ratio is 22.36 :1.

1.2 bar @ 10:1
You are running 17.4 PSI of boost at an altitude of 0 feet. Your motor's static compression is 10 :1. At this boost level and altitude your effective compression ratio is 21.84 :1.

If its that simple then wouldn't the car be making less power now than it was before?

That's pretty low power for the spec like you say and that turbo looks nasty and laggy for the power. Power coming in at that rpm on most other 2.0 engines I build are all making 700+bhp
What compression and leakdown figures did you get? Just thinking maybe there is an issue there.
What is your oil consumption like now and is the catch can filling with oil?
Why is the boost so low, surely you could easily run 2 bar now?

Just a thought Chris, You have a Stage 4 now, but not the bigger pipework that the kit comes with? Didn't you also mention Adrian had "tuned" this turbo?

nah I got the larger intercooler pipes etc installed at the same time as the stage 4 turbo. Yeah they've tweaked this turbo to give slightly more bhp at the top end. Fensport said in their logs they don't see the air flow or anything dropping off towards the top like the torque does on the dyno so that's another thing that makes them think maybe the wheels were slipping.

I don't think this turbo will give anywhere near 2 bar of boost. Fensport said the most they got out of it was about 1.3 when they were using it on their car (race fuel, stock engine internals) and even on the stage 5 that they've just started testing they can only run 1.5 bar so far.

I've not seen dynos from other people using different turbos on a GT86 but I thought it was pretty normal for the power to start kicking in at about 4K RPM on a turbo GT86 (especially now that I'm on 10:1 CR pistons).

Like I said before, they did say they could push it further but I'd asked them to keep it as safe and reliable as possible because its going to be sitting bouncing off the limiter on drift days quite a lot.

Lets face it whatever the dyno results were, someone would be on here saying they could have tuned it better etc etc. I do think the dyno results are a bit misleading and that the tyres might have been slipping, but I don't care about dyno figures enough to go prove that just to satisfy people on a forum. At the end of the day I wanted it to be faster but still reliable, and that's what I've got. So I'm happy :)

Good on ya mate!! Enjoy!!

Just wondering if you have any oil psi readings with the Reimax gears as I've seen people saying they give less pressure at lower revs and that they aren't worth putting in ?

Would like to hear your opinion on this ChrisD or anyone with the Reimax gears .

Noooooooooo the beautiful orange!!!

I m happy Chris to see you back to life XD

We just finished installing the Kaaz 1.5 way diff, in prep for a drift day later this week. I'll report back on whether or not I notice any difference compared to doing this same event last month on the stock diff. Video of the diff install here:
[ame="https://www.youtube.com/watch?v=XPANAX6DkJs"]GT86 Mods #14 - Kaaz 1.5 Way LSD - YouTube[/ame]

Was never that happy with the wrap (peeling in several places) so earlier this week we peeled the wrap off and got the car re-sprayed in "stealth grey", which is the same colour the new Focus RS comes in. Pics below :) really happy with how it looks on the car, but I think I might need to change the colour of the wheels now...

http://s33.postimg.org/howha7pan/20160517_200532.jpg

http://s33.postimg.org/6kvrwp0b3/IMG_9178.jpg

http://s33.postimg.org/iiv1lprdb/IMG_91_X.jpg

http://s33.postimg.org/6yx3waken/IMG_9196.jpg

Wow the car looks great in that color! :thumbup:

Sorry didn't go through the entire thread but how much whp does this car produce? What is the complete setup?

That colour looks great Chris!!


Did you end up with any spare diff shims you might like to sell on?