284 replies to this topic

[paultig]

Hi all, I'm looking at sourcing the stuff as we speak so great timing, has anyone got a definitive checklist of the parts required? Paul.

[The Batman]

USA Saturn Ion/Cobalt SS Supercharger Saturn Ion/Cobalt SS inlet manifold Saturn Ion/Cobalt 2.0 SC throttle body gasket from supercharger to inlet manifold Courtenays gaskets from head to inlet gasket from inlet to manifold pulley pulley bracket Belt z20let injectors injector plugs M6 x 70mm bolts and a pair of M6 to M8 hole adaptors 2 x alternator bolts Pre Rad/charge cooler pro alloy rad charge cooler pump (inlet and outlet 18mm) remap Piping x 6metres 18mm 2 x gromets coolant tank 2 bar map sensor 300mm alluminum pipe 75mm cone air filter This is all for a stage 2 and all i can think off

Edited by joe_589, 28 September 2009 - 04:38 PM.

[vocky]

Can we have some more pics of the area where you have to cut the sill? Please

it's the black line in my pic, simply remove that section, obviously make it nice and neat by following the edge downwards and ideally drill a hole for the corner

[vocky]

Hi all,
I'm looking at sourcing the stuff as we speak so great timing, has anyone got a definitive checklist of the parts required?
Paul.

rcvaughan has just bought everything required and I mean everything

jubilee clips, loom tape etc

I hope he can post his list

[vocky]

not got the time to post any pics at the moment, but it's up and running, just need to finish a few odds and ends. pics will be posted

[JG]

is the purpose of that cut out, simply access? Also what are the sizes of the gromet you used to tidy up holes in the sill? Just making it comprehensive you see Thanks Mr Vocky

[paultig]

Thanks for the super quick responses Vocky and Joe, I'm in that getting that winter project mood but want as much ready as possible so the car isn't off the road for too long. I've just been reading (what seemed like forever) your threads in 'projects' which was very informative, keep up the good work for all us prospective diy'ers who want nothing but the best.

[rcvaughan]

Hi all,
I'm looking at sourcing the stuff as we speak so great timing, has anyone got a definitive checklist of the parts required?
Paul.

rcvaughan has just bought everything required and I mean everything

jubilee clips, loom tape etc

I hope he can post his list

I am working away frm home at the minute but will post my list when I get home. I do like to be thorough!

[vocky]

is the purpose of that cut out, simply access?

Also what are the sizes of the gromet you used to tidy up holes in the sill?

you can either cut your arms to bits [like Joe] or cut the hole larger [like me]

the grommet size depends on the size of hole you cut, but around 45mm

[vocky]

ok a few pics

on later spec engines you need to move the fuel tank vent valve to were it's fitted on early cars



I have mounted the ecu on the bulkhead as the chargecooler tank is bolted to the coolant bracket



I fitted the egr cheater direct to the loom



chargecooler pump wiring added, the fused relay is mounted on the bulkhead for easy access



note the supercharger inlet manifold support bracket is fitted to the block and the egr blanking plate is fitted



make sure you fit the elbow to the chargecooler pipe BEFORE fitting the inlet manifold



the injector and map sensor looms have been extended and the bosch plugs fitted for the z20let injectors



I will take some more pics tomorrow, but the clam is back on for the night, so a final pic from today of the latest vx220 sc

Edited by vocky, 28 September 2009 - 07:31 PM.

[mandarinvx]

the injector and map sensor looms have been extended and the bosch plugs fitted for the z20let injectors

Sorry for butting in with something that's not really related, but can the inlet manifold be removed without disturbing the fuel rail

[rik]

the injector and map sensor looms have been extended and the bosch plugs fitted for the z20let injectors

Sorry for butting in with something that's not really related, but can the inlet manifold be removed without disturbing the fuel rail

not easily, and probably not at all

[vocky]

I never removed the fuel rail to fit the inlet manifold, but you need to remove the two inlet manifold mounting studs to allow that Jon has asked to leave the standard injectors in place (if you intend driving to courtenay's for mapping), I make an adaptor loom to allow the new Bosch plugs to fit the GM injectors. I also fit the z22se MAP sensor on top of the sc, which is why the loom is located in the centre of injectors 2+3 rather than by number 1. Then Jon simply unplugs the z22se MAP and plugs in straight into the new MAP sensor (next to number 1 injector) and they fit the new z20let injectors. If you send your ecu direct to courtenay for the sc remap you don't need to do that.

Edited by vocky, 29 September 2009 - 07:52 AM.

[vocky]

a quick wiring 'to do' list for the conversion; move ecu extend injector looms extend ecu earth cable extend fuel tank vent valve loom extend MAP sensor loom if you are fitting the sc 68mm tb then rewire and extend the tb loom fit egr cheater and fit blanking plate fit the courtenay fan 'mod' - an extra coolant temp sensor, one side to chassis 0v and the other to x2 pin 13 Blue/grey - cut the wire and join the new sensor to the wire going to the fan relay (not the wire going to the ecu) add the charge cooler relay, I use the starter motor as the +12v supply, wire that cable to the fuse and then to pin 30 of the relay, pin 87 goes to the new pump +12v, pin 85 goes to 0v, pin 86 goes to the fuel pump +12v brown/grey (this can be found in the large loom below the air filter on the chassis) The pump will also require a 0v

Edited by vocky, 29 September 2009 - 02:31 PM.

[vocky]

the fuel pressure regulator vacuum pipe also needs replacing with a longer piece, it connects to the small brass take off on the sc inlet manifold (between injectors 2+3)

a few pics

the fuel tank vent valve and extra pipe, this connects to the 68mm tb brass take off - use the original z22se connector as it's a perfect fit


the other end and servo pipe (jubilee clip has since been fitted)



the charge cooler pump



the air filter and charge cooler tank fitted



space gets a little tight with the sc, so the oil catch tank sits near the charcoal filter
you can also see the modified fuel pipes, these have to be bent and moved away from the auxillary drive belt for obvious reasons !



finished

Edited by vocky, 29 September 2009 - 02:46 PM.

[techieboy]

finished

Top work. Can't believe how easy you make it all look.

[JG]

finished

Top work. Can't believe how easy you make it all look.

i fear this is starting something i may regret

[techieboy]

i fear this is starting something i may regret

I'm still haunted by the pain of the charge cooler and hose install I did on mine.

[vocky]

Top work. Can't believe how easy you make it all look.

I have fitted three stage two sc conversions, they are a pain in the butt to do

the front clam / rad / hoses - allow one day
the wiring takes me about four hours - allow one day
the engine work - allow one day

so three days work

Jon and his guys have my respect for having to do these conversions 'day in day out'

[vocky]

forgot to mention, you need to fit an extension to the dipstick tube so that it can be held in place by the sc mounting bolt nearest the tb. courtenay can supply one