My vx220 project

vocky

I had a thought the other day after seeing a longer 2.4 LE5 crank sensor ..... do the pistons clear the crank on bottom dead centre :confused:

Well they did on three cylinders but the 60-2 trigger wheel from the Saab B207 actually touched the piston on number four cylinder at BDC, so I guess the 2.4 LE5 does use a smaller 60-2 trigger wheel which is why it needs a longer crank sensor.

So I will not be fitting the internal trigger wheel at all, it's not required but I was going to fit it just in case of future mods.

vocky

I have added a Stack Air/Fuel gauge so I can monitor the new engines emissions, bit concerned it will run lean due to the 13% extra cc

2_2_SRI_150

lookin good neil,them gauges look good,she is gunna be a beast m8 🙂

vocky

I have also replaced the heat protection for the gear cables, previously they had exhaust wrap and now they have heat shield sleeving

vocky

so managed to drop the engine parts off at Chesmans Coventry for the machining work a few weeks ago, they fitted the Darton sleeves and then bored them out to 90mm. They also zero balanced the bottom end assembly - 2.4 crank, Carrillo rods, JE pistons, TTV flywheel, OEM clutch cover and the alloy crank pulley.

Darton sleeves fitted and block skimmed, the liners are five thou higher than the block to ensure they don't move.

JE pistons zero balanced

Carrillo con rods zero balanced - big ends

and small ends

the GM oil jets required no modification, a pleasant surprise

the brand new 2.4 LE5 crankshaft also zero balanced and the flywheel has had a dowel added

pistons fitted to the block

crank fitted with brand new bearings

vocky

I used some blue tack and measured the valve to piston gaps, exhaust was over 3mm and the inlets 2mm

chain temporally fitted to measure the valve gaps

head fitted and engine cranked over

head removed and the bluetack measured

final assembly could then begin

I have done loads of little mods whilst the engine has been out, this is the webcon vacuum rail and throttle position plug mounting bracket

found another use for the rear towing eyes

electric water pumps new position

saab oil cooler removal adaptor

So my new 2.5 16v engine started first time and sounds nice and sweet 😃

corsaZ22se

looks great! (y)
the throttles look very compact, they might fit my corsa? do they have electronic idle control or is it pre set mechanically?

Matt

Excellent progress Neil. Were you nervous starting it for the first time?

pottsey

superb work neil (y)

vocky

corsaZ22se said:
looks great! (y)
the throttles look very compact, they might fit my corsa? do they have electronic idle control or is it pre set mechanically?

just a throttle stop screw on the throttle bodies, but the mapping also is used to help tickover

vocky

Matt said:
Were you nervous starting it for the first time?

not really, just cranked it over for a few seconds and it burst into life, oil pressure was good as soon as it fired up.

I spent so long sorting stuff out, whilst waiting for the engine parts, that I had worked through everything in my head. The things I was worried about never happened (oil jets fouling the pistons, conrods hitting the bores, piston to valve clearance, oil leaks from the adaptor etc)

evocarlos

very sexual vocky wish i had the money to do something like it

vocky

I would not like to buy another complete engine thats for sure :eek:

evocarlos

i take it that oil jets are not standared on the z22se ?
would they be easily fixable
i remember my R19 16v had them as standard had to remove them to hone the bores

Sjdickso

Just awesome Vocky! When's its going for a on the road test?

vocky

evocarlos said:
i take it that oil jets are not standared on the z22se ?
would they be easily fixable
i remember my R19 16v had them as standard had to remove them to hone the bores

they require the z22se block to be machined, the saab block comes with them as standard.
They simply bolt in place on the saab block, so very easy to remove

vocky

Sjdickso said:
Just awesome Vocky! When's its going for a on the road test?

I took it for a very short drive today, but now it's in bits again because the new heater fan is not working correctly :rolleyes:

I have ordered the correct resistors and hopefully it will be back together late next week.

vocky

vocky said:
took a pic of the Davies Craig temp sensors new location, not ideal as it's supposed to be at the same position as the original thermostat but it wasn't getting warm fast enough where it was on the outlet hose

this new position seems to be working quite well, the Davies Craig controller is sensing the engine temp okay 🙂

corsaZ22se

i need the idle controlled by the ecu to run air con on the corsa. not going as far as you have with the tunning, just love the sound of throttle bodies! i would like to see your car some time when its running.

Matt

corsaZ22se said:
i need the idle controlled by the ecu to run air con on the corsa. not going as far as you have with the tunning, just love the sound of throttle bodies! i would like to see your car some time when its running.

So would most people on here! Every time he's supposed to have brought it somewhere, he ends up breaking something else on it!

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