Stage 1

Jameshs

I am trying to get a list of all the parts to do a stage 1 DIY SC, the reason for this is mainly cost and i feel i can upgrade to stage 2 in a few months. I current have a standard 2.2 so i think i will notice the difference.

This is the list of parts i have so far

pulley - £17.25
pulley bracket - £58.10
pulley belt - £15
larger pulley £49.95
swaping the larger pulley - £63
inlet manifold - £1.60
alternator belts - £2
Remap - £200 plus £85ph on the dyno

All from Courtneys

Plus a M62 plus manifold required

Is there anything else that i would require? What injectors would i need?

FLD

You'd need the inlet manifold alignment bungs, turbo injectors (plus plugs and boots), the manifold bottom bracket. You'll need some wire and heatshrink to extend the loom for moving the ecu. CS recommend removing the pre-cat and having a sport cat fitted too. Think I've got everything there.

Jameshs

Thanks FLD, it was the injectors that i was struggling with. I am getting a 200 cell cat but its only going to be standard bore but that should be ok for the time being.

Does anyone know if the injectors out of the z20let have the same connector as the injectors out of the x20xe?

exmantaa

Z20LET have standard Bosch injector connectors, so a visit to a scrappy should do. But you will need seperate connectors, not mounted on a "rail" like the C20XE/LET had.

You need a new MAP sensor too.

And if you do this all by yourself, why not directly stage 2? Just the chargecooler, a pre-rad + sill piping, but that is not hard work if you have some skills. And you save some on the pulley + removal costs and extra re-mapping...

Jameshs

Just dont have the funds for the stage 2 at the moment to be honest. Maybe in a few months. Ideally a stage 1 should suit me too as i dont want to bite off more than i can chew. Plus it gives me something to do over christmas if i feel the need

How are they mounted then?? any pics?

myhifi

plus MAP sensor bracket, Oil dipstick bracket, Air intake tube and IAT fixing, ....

All DIY but time consuming.

Jameshs

whats an IAT fixing?

exmantaa

That will be a 20mm hole in your inlet tube where the IAT sensor grommet must go.

(If you plan to go Stage 2 later then I would mount the manifold with the laminova's fitted. Then you don't have to remove all that later.)

Jameshs

Will that affect it much with them fitted or removed

exmantaa

It should not be, because when they are restrictive in Stage 1, for sure they are in a Stage 2. (But they are still used in 300++HP "Harrop-ed" engines in the US, so....)

FLD

The map sensor used by courtenays requires the manifold aperture to be sleeved (for a decent job). The US sensor mounting bracket can then be used. I used a P-clip for the dipstick bracket. WRT injector plugs, they are a fiver each from courtenays. Worth saving the hassle.

techieboy

exmantaa said:
That will be a 20mm hole in your inlet tube where the IAT sensor grommet must go.

(If you plan to go Stage 2 later then I would mount the manifold with the laminova's fitted. Then you don't have to remove all that later.)

Is it possible to buy a grommet to use for the IAT sensor as mine is just cable tied to part of the loom in the engine bay and is presumably measuring the temperature of the air in the engine bay and not the intake air. notsure.gif

JohnnyN

techieboy said:

exmantaa said:
That will be a 20mm hole in your inlet tube where the IAT sensor grommet must go.

(If you plan to go Stage 2 later then I would mount the manifold with the laminova's fitted. Then you don't have to remove all that later.)

Is it possible to buy a grommet to use for the IAT sensor as mine is just cable tied to part of the loom in the engine bay and is presumably measuring the temperature of the air in the engine bay and not the intake air. notsure.gif

These grommets are special order from Germany and they are around £10 to buy. I had exactly the same set up as you with it cable tied to the intake pipe and I managed to get hold of 2 grommets recently. I fitted the IAT sensor into my intake pipe and all is fine. The spare grommet that I had went in the post box tonight to another member on here for a project that they are doing.

See here....

viewtopic.php?f=1&t=12865&p=141682&hilit=grommet#p141682

techieboy

Doh! Typical 24 hours too late. Did you get them via GM? If so, do you have a part number by any chance?

I'm trying to find out why the car is pumping out feck loads of black smoke on WOT and am going round replacing sensors to see if that makes any difference. The IAT sensor just hanging around in the middle of the engine bay just doesn't look quite right, even if it is vaguely in the flow through the side vents.

JohnnyN

I just put out an SOS to members on here and VVOC to see if anyone had one in their garage. I ended up with 2 for free. I'll see if i can get the part # today. ;-)

myhifi

FLD said:
The map sensor used by courtenays requires the manifold aperture to be sleeved (for a decent job). The US sensor mounting bracket can then be used. I used a P-clip for the dipstick bracket. WRT injector plugs, they are a fiver each from courtenays. Worth saving the hassle.

FLD, can you be more specific on the sleeve ?

aluminium ?
where from ?

Jameshs

I take the the standard grommit thats current fitted to the intake pipe can be reused?

myhifi

Jameshs said:
I take the the standard grommit thats current fitted to the intake pipe can be reused?

yes

exmantaa

myhifi said:

FLD said:
The map sensor used by courtenays requires the manifold aperture to be sleeved (for a decent job). The US sensor mounting bracket can then be used. I used a P-clip for the dipstick bracket. WRT injector plugs, they are a fiver each from courtenays. Worth saving the hassle.

FLD, can you be more specific on the sleeve ?

aluminium ?

where from ?

The new MAP sensor is too thin for the manifold aperture. I just removed the rubber "grommet" from the new sensor, thickened the sensor stem up with some rubber tubing I had lying around and re-fitted the old grommet over this. The sensor now seals in the manifold and a simple bracket holds it there.

FLD

exmantaa said:

myhifi said:

FLD said:
The map sensor used by courtenays requires the manifold aperture to be sleeved (for a decent job). The US sensor mounting bracket can then be used. I used a P-clip for the dipstick bracket. WRT injector plugs, they are a fiver each from courtenays. Worth saving the hassle.

FLD, can you be more specific on the sleeve ?

aluminium ?

where from ?

The new MAP sensor is too thin for the manifold aperture. I just removed the rubber "grommet" from the new sensor, thickened the sensor stem up with some rubber tubing I had lying around and re-fitted the old grommet over this. The sensor now seals in the manifold and a simple bracket holds it there.

Mines an aluminium sleeve with a rim round the top (top hat style). Its pretty thin (0.5 mm wall) so is bonded in. A better way to do it would be to bore the inlet manifold slightly bigger and make a press fit variant. I made mine myself from a piece of turned down alu bar.