2.4 + 120 amp - IT FITS
OK I've fitted the 2.4 manifold to the Astra - which is fitted with a 120 amp alternator. To make the manifold fit involved carving off the side of the plenum, as per markv's suggestion.
This is what it looks like after sawing off the round blob on the side. The material toward the bottom of the plenum was pretty thin which is why the hole is not quite round (basically I cut too close to plenum.)
The next job was to file down the left over material so that the manifold would fit between the alternator and oil filter. It's a tight squeeze and every mm counts!
A cover plate was fashioned from some 1.6mm aluminium plate - it ended up being 65mm in diameter. One side was roughed up with some 240 grit and epoxied to the plenum, after thoroughly rinsing out the filings from the manifold with plenty of water.
The alternator got the standard Vocky mod however I shortened the bolt which the main cable (and suppressor) connects to. I also just cable tied some rubber hose to the radiator fan support rather than file it down. There was enough clearance plus I'm lazy 😛
In the end it all fitted together quite well.
My 120 amp alternator was bolted to the block with torx bolts - which blows the theory out of the water that only the 100 amp ones use torx head bolts. I forgot to take a pic of the vacuum hose arrangement I used for the brake cylinder .. though you can see a bit of it in the last shot.
