A black 2003 Z20LET Convertible.
Overview
The car was a rather tired example of the turbo breed, but it was at the right price.
Engine
The original engine was using oil and a very tired but all the same I was impressed with the power of the beast. The opportunity came to buy a wrecked Nurburgring Mk5. #20 of #20 in Australia with Z20LEH engine. The chassis was bent in the crash but mechanically it was mostly all ok.
So lots of reading on forums and some help from members of various clubs on line, and I took on the task of seeing just what I could squeeze into the Mk4.
The Nurburg engine, M32 6 speed gearbox, subframe with steering rack, all fit straight in. Swapped engine wiring harness of course as it's pre-Canbus. Did the earth mod on the loom while I was at it. While out, new timing belt (just in case), and water pump "O" ring as the original was damaged in the factory install by the looks, and had been leaking. Who designed that terrible alternator drive tensioner mechanism that is a **** to release???
Kept the old PS pump because of pre-Canbus, and a simple 10mm hydraulic compression fitting patched it onto the later Mk5 rack.
Fitted a gearbox breather with a tube up to area of the fusebox; Overfilled the M32 with synthetic 75/90W oil. Crankcase vent and catch tank mod also included.
Other minor plumbing around fuel tank vent and vacuum piping but all very simple.
Hoped to swap the fuel pump/bucket/filter from the VXR but would you believe the internal tank mount for the bucket is SLIGHTLY different. Only two of four clips line up on the bucket and such a buggar to get in and out, I don't recommend anybody trying it. May swap the tanks one day, but have fitted uprated pump to the old basket. How to on AOC site was very helpful here.
LOTS of long hours spent but after priming for fuel and oil, engine started first pop, and only one minor water leak. Basically a Convertible G VXR. Love the power and that smooth 6 speed gearbox!
Well my Black Beast has been running for some time now, with only a replacement straight through front cat pipe from standard. Also with the standard Mk4 Z20LET ECU without modded mapping, as I just have not had time to fiddle, and only have high performance maps (and a reluctance to risk changing the mapping).
Brakes & Susp.
Did not swap the rear suspension unit as my VXR unit was damaged (the wheel/brake/hub got ripped off in the crash), but I understand the VXR is an uprated rear end in some way. If only bushings maybe I can just swap them. All rear springs and shocks swap no problem.
Front suspension - went to use the VXR struts but one of mine was bent in the crash. So bought Bilstein B8's suit the H with VXR springs. Fits in with slight opening of the mounting hole in the bodywork (1mm) and a little panel work around the hole basically to depress the raised section around the hole. Fits like a glove using the standard plastic retainers. I have some 1mm shim washers in case any slack needs taking up but so far it's fine. MUCH bigger strut top bearings on the H series than the old G. Wheel alignment worked out fine using H series specs.
Audio
In the process of installing a double DIN center section with entertainment unit/GPS etc. It's a tight fit for all that wiring!
Specs
- Year: 2003
- Induction: turbo