Z22SE into Turbo - climb to the top :)

SpaceWalker

I sold all turbo parts and went yet again for naturally aspirated car.

So, the final decision was taken and the project started.
My Z22SE shall be modified into 2.2 Turbo.
The adrenalin obsessed my body and brain.
And here is the list:

Turbonetics T3/T4 Hybrid turbo
Custom exhaust manifold
GM 3 bar MAP sensor
Blow off valve
8 liter Inter cooler with custom 2.5" cooling pipes
Turbo Oil line
Boost Controller
Blow off valve
Slim cooling fans
Electronic turbo timer
Adjustable fuel pressure regulator
EGR catch can (relocate the pipe into the exhaust manifold).
Westgate
2.5" down pipe
High flow intake filter
Coolant sensor
2.5" exhaust system
308mm front clippers upgrade kit with EBC brake disks + pads
APEXI fuel controller (to handle the fuel/air mixture in boost mode, no ignition interference) - After more detailed search the APEXI shall be replaced by HALTECH INTERCEPTOR.
NGK Iridium spark plugs
82 degrees thermostat (92 degrees wide open)
Heat wrap
Oil Cooler
Wiseco Forged pistons
Eagle rods
440cc fuel injectors

The target is 300hp on the wheels.
Parts are already checked and verified.
Few clearance more about the control unit and the fun shall start 🙂

JohnnyN

300bhp at the wheels is a huge amount of power at the flywheel!! Good luck to you. What are you going to use for 'Slim fans'? Courtenay used a vx220 fan on my car.

SpaceWalker

Yeap for sure the jump is big, but it is worth every single dollar spend.
Garret T3/T4 Hybrid Turbo can be used to up to 400hp even a bit more.
The slim fans are exactly from VX220.
Also forgot to mention that an Oil cooler shall be installed as well.
i hope within 2-3 months to complete the project (still hoping, cause my previous Astra GSI C20NE huge tuning took more than half an year).
Also a new suspension shall be needed, but at this stage this is not a primary target.
To complete the heart then shall ensure better handling.

JohnnyN

Don't forget to uprate the brakes too!

SpaceWalker

See my first post,
308mm front clippers with EBC brake disks and pads shall be installed.
I want power, but to be able to deal with it.
Like the cult phrase - POWER IS NOTHING WITHOUT CONTROL 🙂

Also i forgot something very important - this gearbox shall not be good enough for the engine, and this is still an issue and checking for solution!

dodger

sounds a good project, keep us updated as you go with pics

sdbutler10

you want a gear box that can handle that power then look no further. http://www.quaife.co.uk/
its the only company would ever use for a gearbox build.
the spec list sounds amazing keep it updated

SpaceWalker

I will keep you updated guys, i am so exited.
The torque was always inside and part of me as the adrenalin.
The project shall be performed personally in my garage, except the exhaust system.
A lot of photos shall be created.

By any change do we know to what torque the F23/Getrag Gearbox can handle?

winstar

SpaceWalker said:
I will keep you updated guys, i am so exited.
The torque was always inside and part of me as the adrenalin.
The project shall be performed personally in my garage, except the exhaust system.
A lot of photos shall be created.

By any change do we know to what torque the F23/Getrag Gearbox can handle?

there are quite a few VX's running high power though the std gearbox, but they are alot lighter so will be less stressed

rik1083

gets me thinking about twin-charging :think:

Mark_Dj

Keep the pictures coming. Hope all work out well for you 🙂

MikeS

f23 = max 300 bhp imo

heard ppl say that a tuned z20net eats through em

JohnnyN

F23/F25 etc. is the amount of torque that they are safe rated at in the amount of newton meters that they will take from what I have been reading lately.

i.e. F23 = 230Nm Torque.
F25 = 250Nm Torque.

Looking this up on wikipedia it would suggest that the actual rating for the F23 Getrag is 210Nm (155ft lbs)!!

SpaceWalker

Any suggestions how to modify this box?
I saw the difference between Z22SE and Z20NET in the gearbox, both are with F23, but the turbo version is with 3.63 differential i think and 3.94 for the 2.2 and also the gears were a bit longer than the 2.2.

Also with my Moto Guru we made few changes.
Instead of APEXI we shall use HALTECH INTERCEPTOR and we shall split the modification on few stages (cause i shall have summer holiday and i would like to have my car for that 🙂 ).

Buy only the turbo parts (without pistons, rods, head gaskets and head bolts).
Measure one by one the most efficient way to fit the part in the engine bay, to have precise fit with less problems.
T3T4 shall be a TURBONETICS one, already chosen (950$ with shipment included) - this one can handle up to 450hp.
Ceramic clutch with 5kg aluminum flywheel shall be ordered as well.
Install the turbo parts (including oil cooling system) without the Interceptor and run in on 7,25PSI for safety reasons till match the other parts.
6.Install the new pistons, new rods, new crank bearing etc..head gasket....replace eventually the valves, no head modification.
Install the Haltech Interceptor.
Go to the Dyno for testing and hopefully to obtain 21.25 PSI.

sdbutler10

sounds like a good plan you have there mate

Matt

Would the M32 gear box fit?

JohnnyN

Yes it would Matt. Needs some modification to work but it will come good. Vocky has carried out this mod and i'm sure that Jon Shield has done it at Courtenay too.

SpaceWalker

Guys,

After a quick research i found that M32 have been installed on Astra H 1.9 DT and DTH and also on Vectra 2.2 Direct and 3.0 DTH.
Do you know by chance shall it fit directly to the Z22SE gearbox slot (2.2 Direct is the same engine with higher compression ratio).
Does anyone knows something about it?

Matt

SpaceWalker said:
Guys,

After a quick research i found that M32 have been installed on Astra H 1.9 DT and DTH and also on Vectra 2.2 Direct and 3.0 DTH.
Do you know by chance shall it fit directly to the Z22SE gearbox slot (2.2 Direct is the same engine with higher compression ratio).
Does anyone knows something about it?

Vocky did a whole thread on the M32 conversion:

viewtopic.php?f=88&t=7102

SpaceWalker

Huge problems found for the project and the heavy decision to shut down the turbo project is now in place 🙁
Problem identified in the engine bay, really few space there to implement the turbo manifold and T3T4 turbo and also the 76mm turbo pipes. A lot of changes in the engine bay needs to be performed as well, which for sure shall take more than 1 month without a car, which is not good for me 🙁

So the most logical way and option is in place for the engine:

already ordered 2.4 Inlet Manifold
already ordered 2.0 TB
EGR Cheater
Balanced shaft delete kit
Lighter flywheel 5.6kg
Piper Cams 2000-6500rpm
Cold Air intake 76mm
Modified airbox
K&N panel filter
NGK Iridium spark plugs