Johnny's Carlton rides

[Johnny A]

SUMP FOUND!!!!!111111oneone
After spending hours contacting breakers with no luck (either people had them and wouldn't split from engine or don't bother stocking as no one wants 2.0/2.2 spares like this) I spend a further 30mins and found every car breaker search engine I could and entered all my details (name, email, chest size).

All day I had nothing, then a call comes in and someone has one!!! Cost me £75 tho!! Total rip but I am desperate.

Anyways after tremendous amounts of cocking about I managed to get a few hours in on the engine:
Turbo oil return modified to clear engine mount


Manifold all done


Some basic porting done, nothing fancy


Manifold all bolted up with new gaskets, studs and nuts


Screamer pipe done (smaller pipe on left), downpipe about 40% done



Another shot, I think I will make the screamer pipe a little longer, don't want to set fire to anything apart from tarmac!


Block breather got a little treatment too, it now hugs the engine closer to clear the manifold and downpipe. Its still very close though with only around 3mm inbetween the pipe and downpipe at one stage, not to worry though as the downpipe will be heat wrapped


Welds on downpipe flattened and two lamda bosses added


The Z20LET management uses two lamda sensors, a primary one and a secondary which the ECU uses to compare readings to make sure things like the CATs are working. For the time being I will connect both but I am hoping once it has its remap the second lamda can be made redundant so I can use that boss for a wideband.

I have now reached the stage where the engine needs to go into the bay to continue, but without a sump for at least a few days I will have to hold fire.

Instead I will transport the engine to the unit tomorrow and work the shell!

[Johnny A]

Engine comes out the garage for transport:


Add an engine and hoist to the back for extra lowness:




Like a glove!


I make a makeshift clutch setup to make sure the slave cylinder is still working, which is does 

[doz]

Looking good. How big is that turbo? It dwarfs the two I've got on the LC!!!!

[Johnny A]

Looking good. How big is that turbo? It dwarfs the two I've got on the LC!!!!

Its a Greddy/Mitsubishi TD06H-20G turbocharger, on a 2.0 16v it will max out around 2.5bar of boost or 550bhp ish.
Its CFM is around the 650 mark

Or I could just agree that its a pretty big turbo lol

[doz]

I take it the power will come in with just gentle BANG! then 

[Johnny A]

Floor it:
Nothing nothing nothing nothing nothing nothing nothing nothing nothing ditch

[doz]

That sounds like fun!!!! I had a mate with a scooby doo who spent thousands having a gurt turbo thrown on it. Drove it for about 3 months before he took it back and spent another fortune having a smaller one fitted. It was silly quick while on boost but when he was just pooterling along in traffic he got fed up having to change down 2 gears to get up the slightest hill. To quote him he said "man my 1lt Fiesta had more puff than this pile of poo" I think he was referring to it off boast. On a slightly different note. I had a ride out in a mates Holden HSV the weekend. 5.7 V8 with a blower fitted. 580 BHP. Fek did that go. So a Carlie with 550 should be epic. 

[Johnny A]

No no I won't be running 550bhp, only 350bhp... anymore needs a forged bottom end.

This turbo is a Greddy unit (variation of the Mitsubishi unit) which spools quickly as it is, but then ATS racing in the US get it and change the compressor housing and compressor to suit a 2.0 16v MR2 Turbo. ATS then sell it as part of one of their biggest turbo kits available.

ATS *claim* that it spools at the same revs as the standard MR2's turbo on standard boost, but obviously the boost pressure would then increase once the boost levels are raised.

I did a little snooping and found out that a standard MR2 turbo reaches full boost around the 2500rpm mark. Target boost pressure will be around the 1.2 bar mark which i'd expect to see around the low 3000's which is pretty good.

[doz]

oh right. Seems I've had a similar thing done on the LC turbos. I've had the the housings machined so I could fit T28 internals. Made a low of difference. Spool up time is much quicker and holds on to the boost longer.

[Johnny A]

Here is a power graph from an MR2 turbo with this turbo fitted @ 16psi


As you can see its still got plenty of power low down, bit of a flakey graph but from what I understand its just a chipped ECU not a live mapped one.

[Johnny A]

oh right. Seems I've had a similar thing done on the LC turbos. I've had the the housings machined so I could fit T28 internals. Made a low of difference. Spool up time is much quicker and holds on to the boost longer.

Sounds good, had it rolling roaded??

[doz]

Not on the rollers yet but ahem we had a fiddle of the ECU which has released a lot more ponies. So hopefully with the head work and the inlet work I'll see 420-430

[Johnny A]

You upped the boost levels at all?

[Johnny A]

Update:
Past few days have been totally dragging, work has taken ages.
Yesterday I spent pretty much the whole day removing, modifying and reinstalling the pedalbox and today I spend all day restoring the engine bay.

Trail fitment of gearbox:



Bought a second hand 2.0 subframe and cleaned it up:


It took 5 hours to modify this cable-operated pedalbox to accept an Astra-G hydraulic clutch master cylinder, but the end result is spot on:


I have intentionally widened the pedal to piston ratio to compensate for the narrow biting point of my new paddle clutch:

A 6-paddle cerametallic custom made by CG motorsports, another work of art that will be hidden inside the engine!

[Land-Barge]

That looks expensive

[stemo]

Considering its only two pages long at the minute I'm impressed with this build already, keep the updates coming should be awesome when it's finished! 

[Johnny A]

Does anyone still check this out??

Update: Been busy of late working on my sisters Astra Coupe Turbo, that took a while weekend!!
This Saturday I moved my 4.6 Range Rover V8 from my friends garage to my unit

Update:
I had to fit the PAS pump off the old C20LET engine (The Z20LET's never had these), it bolted up fine but the exhaust manifold fouled it so some hacking was needed:


Coolant pipework from a 2.0 8v Carlton, some tweaking was needed and its rather tight!



Today I needed to finalise the engine mounts on the Carlton, it would appear a slight incompatibility in the Z20LET engine mounting. Rear box mount was fine but the two fronts cause the sump to foul on the subframe and the inlet to foul the steering box, to get those to clear I had to move the engine forward about 1 inch. This would appear to be a design alteration that Vauxhall made to cure these problems and they more than likely altered the subframe mounts to achieve it, so I did the same.

I did much tweaking as I wanted the engine to sit fairly low in the bay (so the turbo doesn't melt the LC bonnet vent) but not low enough to rip the sump off over speedbumps. After 2 hours of yoyo'ing the subframe in and out and tweaking the engine's position with the use of trolley jacks, bottle jacks and engine cranes:







Sump to subframe interaction, pretty tight!

[Pedro]

Looking great matey!

Stick at it and get it finished this time, so we can see it at Billing next year, yeah?

[24vman]

Johnny - Your engine mounts are fitted the wrong way around.

I phoned then when I fitted mine, and they said big washer up.

[Johnny A]

Meh

[24vman]

Meh

?

[Johnny A]

Its a young persons way of saying 'not bothered'

[24vman]

Its a young persons way of saying 'not bothered'

Define "Young" 

[Johnny A]

You know what 'meh' means

[24vman]

No, just wonder why you decided to fit them washer down.

What was you thinking ?