project boost bus

pottsey

z20let injectors arrived today ,they have only done 6k miles as well

im still waiting on some parts to arrive that ive ordered from courtenays.
but ive done a little spending,popped over to see nickyb today and picked this beauty up
weapon r manifold 4-2-1,200 cell milltek sports cat,this used to belong to atomx which if I remember rightly he had on his zafira

one of the new top hoses

some fresh coolant and oil

febi top mount kits and droplinks

and some new bilstein shocks

i also picked up a spare aircon rad off nick as well ,which will be going to an engineering place to have 2 19mm outlets alloy welded in to use as the chargecooler[/QUOTE]

pottsey

few more updates
had a ride over to courtenays this morningto get this lot
got some new lowerings springs 40mm all round kw springs which is basically the same as the weitec ones i was originally gonna get

stage 1 supercharger belt,top hose,and a new inlet gasket as the one i originally got was misshaped

idle pulley assembly,stage 1 pulley

map sensor blank,2 alignment bungs,relay for the water pump,map sensor,dipstick bracket,alternator bolts and washers and inlet manifold to head bolts and washers

so ive pretty much got everything now just need some coolant hose ,clips etc.battery tray fabricating out of stainless.
picking the chargecooler up monday which ive used a spare aircon rad which ive had 2 19mm outlets welded into it

pottsey

few more bits have arrived
heres the aircon rad that will be the chargecooler which i got off nickyb as a freebie (cheers nick)had the old aircon pipes took off and welded over ,and 2 19mm outlets fitted which cost me £20 to have done
EDIT I know the outlets aren't in the ideal of places but I couldn't get them at the top and bottom as they would foul on the bodywork still does the job ok

the boost gauge ,which can be lit in white or blue ,which will go nicely which my white dash

and the all important badge :rock:
[/QUOTE]

pottsey

update time
went over to michael derry's today where we set about fitting these,a big thank you mike your a star

right fitting these wasnt easy at all,as nickyb well knows as it came off his
firstly the cable tray has to come out ,then the bracket which holds the water pipes had to come off ,the aircon pipes came out ,they needed to come out anyway for the s/c conversion

before

my original exhaust manifold gasket had to be dremeled to suit the weapon r manifold outlet holes

the difference in the 2 manifolds

the engine mount was then took off and 3 off us pulled and levered the engine forward about 3" whilst michael slipped the weapon r in

once that was in and bolted up then d/pipe was next ,next problem was that it was knocking on the sub frame on the bend so we bent the subframe enough so it didnt foul on it

as it was joining the magnex centre ,i thought it would be ok as magnex is 2.5" ,yes it is but not at the cat end so i need to get that sorted as it blows a bit
but other than that it sounds bloody awesome

pottsey

battery cables arrived today for relocating the sports battery

pottsey

took a trip over to see cavaddict today to get the ecu moved A BIG BIG THANK YOU STEVE YOUR A LEGEND
got to his at 4 oclock and left there at 8.30.what a job and half it is moving the wires
1 ecu plug was ok the other needing extending quite abit ,2 of the injectors needing lengthning also the throttle body wires needing extending and the air intake temp wire,so quite a lot of wires think there was about 20 ,also needed a new earth for the ecu
so now all i need to do is fabricate a bracket for the ecu as its currently cable tied to the brake pipes
anyway heres the pics of the spaghetti

the donor loom

and back together again ,just need to get the cables wrapped in some convoluted wiring sleeve to tidy it up ,you can just see the ecu near the abs unit with the green cable ties

pottsey

ecu is now off ready to take to courtenays in the morning for remapping

also got this today uprated gearbox mount ,to take some stress out of the engine ,will stop a lot of engine movement
this is one of burt150 mount that he made up ,which I bought of another member on here

pottsey

well no turning back now lol.dropped the ecu in at courtenays this morning for remapping ,should be ready in about a week ,but i'll probably pick it up in 2 weeks that way it gives me 2 weekends on it .dont want to rush it and make a balls up
anyway here it is ready for the conversion

rad cover,air filter,inlet pipe,throttle body,rocker cover breather pipe all off .

eventually the breather pipe will go to a catch tank ,instead of the small filter ,inlet pipe and silver silicone hoses will make up the pipe off the s/c
time for the bumper to come off so i can remove the bumper bar to get to the aircon rad ,which is coming off as i have another aircon rad which has been converted to the charge cooler

think i may have to re route the cold air feed to the opposite side as the filter will be where the battery is
and its off

aircon rad off.aircon compressor off ,that wont be going back on

next up the inlet manifold ,came off nice and easy

also now the inlet manifold is off i can check to see what amp the alternator is ,and luckily for me its the 100 amp one which means it doesnt need swapping ,just a minor alteration so the inlet manifold fits snug against it
ready to be tucked away till tomorro

starting to get a few spares now lol

pottsey

done a bit more today
inlet manifold supporting bracket on

next up is to get the fuel rail off so i can put the z20let injectors in

one fuel rail off

z22se injectors -top
z20let injectors -bottom

z20let injectors now in the z22se fuel rail

inlet alignment bungs in place

and its in ,bit of a squeeze

fuel rail back in now ,just need to get the new plugs wired into the loom,might need to modify the fuel pipe ,will see once i get the charger sat in place

also need to get a bolt to secure the bracket to the manifold

pottsey

bought 4m of coolant hose today but only paid for 3m cheaper than i thought only £2.50 a metre from halfords,and a nice selection of hose clips ,as i need 8 for plumbing the c/c system

also done a bit more today,time for the last easy oil change as when the charger is on i wont get to the oil filter so easy

think it needed changing

also modified the water pump bracket so it fits properly as there is a plug in the way

water pump in place but not tightened up yet as i still need to fit the pipe work

pottsey

well got the ecu back and the charger with the new pulley ,whilst speaking with jon at courtenays he reccomended cleaning the lamnivora cores out before everything gets fitted in ,so im gonna whip the inlet manifold off and take them out and give them a good cleaning with some jizer

charger with new pulley on

as recommended by jon at courtenays to clean the lamnivora cores out ,so i took the inlet manifold for the 2nd time,getting good at it now lol
endplate off with the lamnivoras in place

cores out ,could do with a clean so got a tin of gunk and gave them a soaking ,then rinsed them out and left them to dry
before

after

before

after

dirty and clean

manifold back on with the bottom hose on ,as you can see its quite tight on the fan housing,so i trimmed a bit of the fan housing and put a metal sleeve on the bend of the pipe to protect it ,will cable tie it in place once i run the rest of the pipework in .there is plenty of clearance between the fan still so it wont catch on the pipe

got the modified alternator on ,had to take the plastic cover off and then trim the stud down so it doesnt come in contact with the manifold ,as you can see its quite tight down there

also got the idle pulley /bracket on ,ignore the top hose as that will be coming off and there will be 2 new pipes re -routed over the charger

pottsey

bit more done after work today
got the aircon rad which is now being used as the chargecooler on with the pipes on either side

the filler neck/reservior which came off the chevy cobalt which came with the charger

pipes on the water pump

starting to look a bit better now getting ther bits back on

will bolt the ecu bracket up tomorro as i ran out of light[/QUOTE]

pottsey

got the ecu bracket on and ecu all bolted in place

pottsey

right started out at 8.30 this morning ,got the exhaust flange/sleeve fitment on ,hopefully it wont blow

as the map sensor is too small for the hole in the inlet manifold i put some tape round it then put the orange rubber bit on
fits a treat once i modified the map sensor bracket

top hose off

battery out

then on to sorting the battery cables out ,went to b+q last night and bought a plug socket backing unit and a blanking plate so i can put the postive terminal in it

nicely tucked away under the old battery tray ,will probably paint it black although once everything else is in it wont be seen much

pottsey

sandsy came round to sort the wiring out ,here he is wiring the injectors in

supercharger in ,top hose on and tidying wiring up

brake servo pipe being connected

pottsey

also in the above pics as the fuel rail is too near the charger i cut the pipe and joined it with fuel hose
and this is where its at now

battery tray is here but needs a bit grinding so i put it in the airbox for now so i can lock the car
bit of a mess

just had to get this on

the only problem we came across is i was originally gonna use my 2.2 t/b ,but the spacer which i bought from courtenays ,the bolt holes dont line up with the t/b :grrrrr:,but even if they did the 2.2 t/b holes dont line up with the holes on the s/c .
so im back to my original plan of using the 2.0 lsj one ,so need to swap the wires round tomorro ,also the 2.0 one has a pipe take off in the way of the power steering reservior ,so i removed that and got in touch with my mate moose,so a few phone calls later we was off to wisbech to his workplace where his mate drilled the hole and then tapped it and put a 10mm grommet screw in ,all sorted there at least i can get it running tomorro

pottsey

well everyone sorry to disappoint you all but its all in but it dont start ,im absolutely gutted .i'd like to take a moment to thank sandsy who has done an absolute blinding job the last 2 days ,sandsy you are a diamond geezer i owe you big time
any way everything is all in all wires done pipes on its getting fuel upto the rail ,the only thing we can think as to why it wont start is the injectors i need to get in touch with courtenays to find out if they should be wired the same as the original injectors or weather they need swapping
heres a few pics from today
new coolant temp sensor

battery tray

air intake /cone all on

water pump wired in

and this is where we left it ,too dark to do anymore the battery had to be jumped as well as its been stood since october ,will be fine once it gets some charge in it

pottsey

just had it code read it came up with
p1512 throttle postion adaption error
p1682 electronic throttle control malfunction
guess thats the problem

pottsey

it runs

but not how it should be ,as we were getting the 2 codes coming up for the throttle body it lead us to think the t/b is at fault so we got another t/b put it on ,turned the key..... nothing ,still the same .
so we got in touch with courtenays and explined what was what jon ran through a few things ,still none the wiser then we was gonna run test to see if there were any breaks in the wire between the ecu and t/b ,but as we didnt know how the wiring on the ecu plug corresponded with the t/b we left that .

so got hold of another standard ecu transponder and chip,put the ecu on turned the ignition on and the t/b worked so we done the transponder and chip ,turned the key and hey presto it fires into life ,runs a bit rich as can be expected on the non mapped ecu ,sounds a bit lumpy but its a good sound lol.
so im onto the phone in the morning to courtenays to get it sorted

pottsey

right big update time before everybody points the finger at courtenays its nothing to do with them .
its a human error on my behalf ,i took the remapped ecu off ready to take to courtenays only to notice there was 1 pin bent over ,so i straightened it plugged it all back in ,put my original chip and transponder in and turned the key and all is good woo-hoo.
so ive rung jon but hes busy with a customer so waiting to gert in touch with him to tell him the news
anyway started up fine revs were a bit erratic for a few moments then it settled down ,topped the coolants up and took it for nice steady drive round the block ,without the front bumper.so im currently putting everything together and will update
well here it is all in

took it out for a little drive didnt go stupid ,but it has decided it doesnt like the belt

thats problem no 1 ,the next problem is because the charger sits so close to the power steering reservior its rubbing on it and is causing it to leak :swear:,so that needs addressing before i drive it anywhere.
i only took it for drive for about a mile but god does it sound awesome ,the power is unbelivable deffo big grin factor
regarding the belt im guessing the pulley on the charger isnt running in line with the rest of the pulleys

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