79 replies to this topic

[chris_uk]

everything but the Header Tank is here now..

Bosch PDA 12V water pump (with plug end for to wire in)


Dipstick braket bolts.


Length of vaccum hose


I called alloy fabs this afternoon and they are going on holiday right when I need it for. so i wouldnt beable to get one until july! so im going to have to come up with a solution for that one.

[chris_uk]

little update now...

I got back from france on monday afternoon and just couldnt face doing anything that night, so tuesday morning came and i started on the car.

First things i did was remove the clams, once they were off i started on the chargecooler, i got the larger one so the pipes were on the drivers side. Everything went fine in fitting it and its currently bolted onto the rad with some thick double sided tape inbetween.





next thing to do was run the pipes through the sill, this was supposed to be the hardest thing to do, and i think it probably is, i managed to get the pipes through by pushing a piece of plastic pipe through and pulling the chargecooler pipe back, worked a treat



next thing to tackle was the removal of the old stuff, the inlet manifold, throttle body and the intake pipe all came off, i removed the ECU and put them all in a box at the back of the garage.

i then started on the fuel rail and removed the injectors, (note, a little bit of fuel will come out) also take care not to let the little O ring come off the injectors and fall into the cylinders.

once they were out i started going about changing the altenator, i had a 120 amp with a suppressor before, so i installed the 100amp and noticed that it still needed a suppressor on it so the sc manifold would fit, i also grounded off the bolt so it didnt foul the manifold.

then i started bolting on bits, the pretensioner bolted onto the side of the altenator, the manifold was put in place (temp) so i could see that nothing was fouling it, i also put the 90 degree bend on the manifold (my brother wanted something to do so let him do this)




then it was time to fit the charger on top, once on i moved the top hose out of the way, then i moved the fuel pipes out of the way. bolted on the sc throttle body and made a new intake system out of my old one.

that was it for day one.

[chris_uk]

wednesday

today saw me up early (again) and out to the drive, i first started by fitting the intake pipe i made propperly and so it fit snug.

then i mounted the ECU and plugged the harness into it.



i then replaced all the old injector plugs with the new ones



extended the injector loom and the MAP sensor



and thats where i am atm, i have run out of wire for the other sensor, and i cant really do much more until i get the header tank.

[RobNA]

Good progress there, keep posting the pics

[rsg]

good detailed build chris where did you get the charger from??

[chris_uk]

quick question, and quick pic,

when im plumbing up the chargecooler pipes etc, does this look about right?



the charger i got from courtenays, well the entire job lot i got from them tbh,

[Seb.F]

quick question, and quick pic,

when im plumbing up the chargecooler pipes etc, does this look about right?

Yes mate that diagram is fine. Exactly how mine is I think.

[chris_uk]

oh good, that means i can crack on tomorrow then.. i should be pretty much finished then by tomorrow.

[rsg]

the charger i got from courtenays, well the entire job lot i got from them tbh,

Cool, didnt realise they sell all the parts in kit form. Do you mind PMing me the costs??

[davemate]

courteny are very careful not to call it a kit, as this implies that it comes with warrenty and some sort of returns. I also sent chris a message asking for the bits needed. Although i am only doing stage 1 for now. and details on how to do the dual pass mod? as this looks interesting- did you get it done somewhere?

[chris_uk]

this is a list i compiled with the prices, everything with a '#' comes from courtenay apart from

large cotton filter
breather filter
egr blanking plate
corsa top hose (which isnt needed anyway)
charge cooler header tank

i went for the alloy fabs header tank so that would be £80 not £190 and i didnt bother with a oil catch tank.

hope this helps.

[chris_uk]

also as dave said, they wont call it a kit but if you tell them what you are doing they will be more than happy to help

[chris_uk]

some more pics from today

chargecooler is now in place and ready for the radiator to be piped up propperly


you can see here how much i had to cut into the front structure to get them both to fit propperly


overview of manifold


piped up



neater wiring

[chris_uk]

today has been a busy day lol

i painted the toeing bar silver, but it looks sh** so im going to paint it black



rad cowling back on


supercharger fitted

[chris_uk]

bunged up the hole in the top of the manifold with some tigerseal


fuel pipes moved well out of the way now so not to foul the belt


with the excess stikaflex i tried to reinforce the sides which tend to split



all wiring all neat and tidy


general overview of the install







1. fit header tank
2. plumb pipes from header to manifold to chargecooler - DONE
3. alter the throttle body wires to work with the 2.0 s/c TB - DONE
4. extend the MAP sensor - DONE
5. remake intake system - DONE
6. install relay for the chargecooler pump - DONE
7. install chargecooler pump - DONE
8. send off ECU for base map putting on - DONE
9. re-route fuel lines - DONE
10. mount ECU - DONE
11. extend injector wires - DONE
12. install fused relay for pump

[chris_uk]

ive been told the 1270 belts might be abit to tight.. whats everyones thoughts?

[Seb.F]

My 1270 after a trackday has pulled the charger down, so I'm getting a 1280.

[Mike (Cliffie)]

Too tight. See Seb.F's post on SC issues. Diagram is OK as long as you swapped the laminova cores around and they are in the right way ie. two large holes to the outside two small holes to the middle. You did remove the orange seal over the inlet before you bolted the SC on I take it? Thanks for documenting this build, I am excited for you..... Have you had the ECU flashed by Courtenay's as yet with a base SC map?

[Seb.F]

You did remove the orange seal over the inlet before you bolted the SC on I take it?

[chris_uk]

yea i did