X20XEV to Z20LET (in Brazil)

[Iran]

Hy guys!!!

My first post... (sorry if I made some bad thing below,
including the grammatical errors).

I am a happy brazilian guy because I had the chance to get some parts of engine Z20LET (intercooler, some pipes, fan) with the help of the Jason and Astralopiteco! :clap:

In Brazil the Astra Turbo version is not commercialized, only the XE20EV (2.0 8V flex fuel) and C20SEL that is similar to the XE20XEV (2.0 16V).

I bought the turbocharger of the Astra VXR (from Regal Autosport/UK).

Now few steps lack me to install the turbo system.

If somebody will be able to help me with pics, would be very grateful!

I haven't idea how you make the linkings of oil and to water (hose to turbocharger return, pipe oil to turbocharger feed, hose, bend, to turbocharger cooling return, hose to water to turbocharger feed, and the hose indicated in the drawing)

http://img79.imageshack.us/img79/2592/anyc00116re2.th.jpg (http://img79.imageshack.us/my.php?image=anyc00116re2.jpg)http://img404.imageshack.us/img404/1307/dsc07963mu3.th.jpg (http://img404.imageshack.us/my.php?image=dsc07963mu3.jpg)

Thanks!!!

[InsaneAsylum]

you can get the oil feed from the side of your engine closest to the firewall. there's a plug in the block near the pressure sensor and oil filter which is a M14x1.5 fitting.

you will have to tap the sump to create an oil return

you should be able to intercept any water line, in fact there's a water line that goes into your throttle body to prevent icing. i would put a t-piece there in order to get water to your turbo. there's also a water line that runs across the top of the exhaust manifold next to the rocker cover. this might be useful to get water into your turbo.

you might also want to ask on migweb.co.uk and speak to your brazilian friend mattheus on migweb who has lots of information about turboing brazilian chevrolet's

[Iran]

you can get the oil feed from the side of your engine closest to the firewall. there's a plug in the block near the pressure sensor and oil filter which is a M14x1.5 fitting.

Thank you, InsaneAsylum!!!

The plug what you spoke is some of these of the pic (1) or (2)?

http://img217.imageshack.us/img217/5742/dsc07988na3.th.jpg (http://img217.imageshack.us/my.php?image=dsc07988na3.jpg)



you will have to tap the sump to create an oil return

http://img404.imageshack.us/img404/3561/astraturbo12mx8.th.jpg (http://img404.imageshack.us/my.php?image=astraturbo12mx8.jpg)

I thought about making something similar. The original return is soon above, right?



you should be able to intercept any water line, in fact there's a water line that goes into your throttle body to prevent icing. i would put a t-piece there in order to get water to your turbo. there's also a water line that runs across the top of the exhaust manifold next to the rocker cover. this might be useful to get water into your turbo.

In engine C20SEL does not have the water line that goes into throttle body. Is the water line that runs across the top of the exhaust manifold next you to rocker to cover, in the pic?

http://img177.imageshack.us/img177/6171/dsc07919oa4.th.jpg (http://img177.imageshack.us/my.php?image=dsc07919oa4.jpg)



you might also want to ask on migweb.co.uk and speak to your brazilian friend mattheus on migweb who has lots of information about turboing brazilian chevrolet's

Thank you, I'm going to look for Matheus, and ask him!

Regards!

[auzvectra]

i beleive it's number 2 for the oil supply.
on the z20let, it returns into the side of the block but. as long as it returns above the oil level in the sump, this oil must not be restricted from returning in any way!!!

[InsaneAsylum]

yes it's definetly number 2 for the oil feed

that is a water line you have circled. you might be able to make that work with your turbo, i would ask on migweb just to be 100% sure of it's suitability.

good luck with your conversion.

[Iran]

i beleive it's number 2 for the oil supply.
on the z20let, it returns into the side of the block but. as long as it returns above the oil level in the sump, this oil must not be restricted from returning in any way!!!

Thank you! I hope it returns above the oil level in the sump, preventing that turbocharger smoke!


yes it's definetly number 2 for the oil feed
that is a water line you have circled. you might be able to make that work with your turbo, i would ask on migweb just to be 100% sure of it's suitability.
good luck with your conversion.

Perfect I already found the Matheus in migweb (Matheus428)!
Thank you InsaneAsylum!!!
Regards

[Lt Ketch]

Keep us posted on how you fare with this project!

[Iran]

Keep us posted on how you fare with this project!

Of course!!! Thank you!

[poita]

yes please just us posted, havin an X20XEV myself will be interesting to see how this goes :D

[InsaneAsylum]

theoretically it will work well. there are 2 possible snags i can see and one of them is maxing out the ecu's capabilities, the other one is high compression.

although the c20sel and c22sel run 9.6:1 which is a lot closer to the calibra turbo's 9:1 than the x20xev's 10.5:1 is. so you could probably run between 5 and 10 pounds boost providing the ecu could accurately read the amount of air that was getting sucked in and provide the right amount of fuel.

i wanted to do this a long time ago, i did a lot of research but i didn't have the time, space, money or resources to stuff around and i needed my car on the road.

[auzvectra]

that is a very good point insane, useing the stock turbo but, disregaurd the boost control solenoid (at least at 1st) and just run a vacuum line strait from the snail to the boost actuator, this will give u a nice 4psi.
this will let u know how it's going to go, after that u could put an aftermarket ebc on it, or just a bleed valve or sumpting.
you will need to block up where the vac line returns to on the intake of the turbo but.

[Iran]

theoretically it will work well. there are 2 possible snags i can see and one of them is maxing out the ecu's capabilities, the other one is high compression.

although the c20sel and c22sel run 9.6:1 which is a lot closer to the calibra turbo's 9:1 than the x20xev's 10.5:1 is. so you could probably run between 5 and 10 pounds boost providing the ecu could accurately read the amount of air that was getting sucked in and provide the right amount of fuel.

Because these things I think that has way to solve the problem.

Change injectors for others with a bigger outflow (Vectra X24XE flex fuel injectors are + 30% than Astra C20SEL), managing the injection time parallel the ECU and delay the point of the engine (is it right?), with a controller.

Or change the fuel (petrol for ethanol).


i wanted to do this a long time ago, i did a lot of research but i didn't have the time, space, money or resources to stuff around and i needed my car on the road.

For all these reasons until today I did not have hope to make, but later that I gained the parts, a challenge became!

Poita I'll register all the steps that I make and keep informed you!

[Iran]

that is a very good point insane, useing the stock turbo but, disregaurd the boost control solenoid (at least at 1st) and just run a vacuum line strait from the snail to the boost actuator, this will give u a nice 4psi.
this will let u know how it's going to go, after that u could put an aftermarket ebc on it, or just a bleed valve or sumpting.
you will need to block up where the vac line returns to on the intake of the turbo but.

I understood (I think)! It Would be something thus!

http://img95.imageshack.us/img95/6434/dsc07963mu3zu3.th.jpg (http://img95.imageshack.us/my.php?image=dsc07963mu3zu3.jpg)

What is EBC?

Thank you!

[AF1R]

offtopic here, can u post a picture of ur car, looks hot in ur advatar, nice wheels man.

[InsaneAsylum]

I understood (I think)! It Would be something thus!

http://img95.imageshack.us/img95/6434/dsc07963mu3zu3.th.jpg (http://img95.imageshack.us/my.php?image=dsc07963mu3zu3.jpg)

What is EBC?

Thank you!

EBC is electronic boost controller

example: http://www.g35turbo.com/images/Profec-B-spec-II-Boost-controller.gif

[Iran]

offtopic here, can u post a picture of ur car, looks hot in ur advatar, nice wheels man.

offtopic?! It happens.. hehehehe
Thank you!

http://img339.imageshack.us/img339/5874/dsc08095ap2.th.jpg (http://img339.imageshack.us/my.php?image=dsc08095ap2.jpg)http://img99.imageshack.us/img99/8683/dsc08119ex7.th.jpg (http://img99.imageshack.us/my.php?image=dsc08119ex7.jpg)http://img339.imageshack.us/img339/7978/dsc06411oy3.th.jpg (http://img339.imageshack.us/my.php?image=dsc06411oy3.jpg)

In Brazil, the people call (this model) "Astra locomotive" (Astra G facelifit).


EBC is electronic boost controller

example: http://www.g35turbo.com/images/Profec-B-spec-II-Boost-controller.gif

Excellent!!!
How much would be the cost of this controller?
Apexi (USA) it seems that also it manufactures.
Is better I to leave the fixed pressure or to use the electronic boost controller?

[InsaneAsylum]

as auzvectra mentioned, stick with the fixed pressure of 4psi which the wastegate gives you at the start.

make sure everything runs ok and that you are happy with the conversion, then using an ebc you might want to slowly increase the boost levels.

you will need to keep an eye on the air:fuel ratio as you know what eventually happens to a lean running motor

[Iran]

InsaneAsylum

Perfect! To leave fixed pressure of 4psi how I can make it? Start fixed in the direction of the arrow in red or the arrow in yellow?

http://img243.imageshack.us/img243/2408/dsc07963mu3fn6.th.jpg (http://img243.imageshack.us/my.php?image=dsc07963mu3fn6.jpg)

Thank you!

[InsaneAsylum]

bypass the solenoid. the bit with the yellow X should hook straight up to the wastegate canister.

i would also think there would be some form of adjustment through the threaded wastegate shaft.

auzvectra?? what do you have to say?

[astralopiteco]

Hey guys, thank you for helping my friend Iran!

As InsaneAsylum mentioned, the ECM used in the Brazilian C20SEL (Bosch Motronic 1.5.5) does not control the boost, so that an aftermarket EBC will really be necessary in case he doesnt want to leave it fixed. The starting pressure of 4psi is a very good idea, considering that the C20SEL has no forged internal parts and some caution with the amount of power after the conversion is highly recommended.

So far, Iran has all the air intake piping, the IC (all kindly given by Mohawk) and the vxr turbocharger. The currently pending issues are:

1) Connection of the pipe from the IC to the throttle body, as he doesnt have the induction manifold yet. Anyone has one spare?

2) The connections of the oil feed and the oil return pipes respectively to the turbocharger and to the engine block. Notwithstanding InsaneAsylum's clarifications, could anyone be so kind to shoot some photos of the original connections from any SRi Astra with factory turbo, including photos of the oil cooler and its connections? Thanks!

3) The connections of the water feed and return pipes to the turbocharger and the locations were the water is collected and returned to. As above, if someone could post some pics it would be a great help.

4) Connection of the turbocharger to the exhaust system. This is an issue as well, because the C20SEL doesnt have the pre-cat as the Z20LET does. If someone from sydney has such pipe and its iron brace as a spare (I've seen that many of you guys remove the pre-cat), PM me so that I can get it and send to Iran.

5) The extra petrol will be provided by swaping the original injectors to the ones used by the Brazilian 2,4 litre 16v vectra. The fine tuning will be done by remapping the ECM.

6) Regarding the ignition, when remapping the ECM the necessary delays will be adjusted, although C20SEL's compression ratio isnt that high and if this really turns out to be an issue, there will always be the possibility to use ethanol, which is available on every petrol station in Brazil.

Cheers!

[auzvectra]

he should be able to run the original manifold, just turn the rubber hose to face the other direction, so it points towards the back of the motor.
my motor is striped, so i can get most of the pics easily, the oil cooler is just on the back of the block, and is a heat exchange to the coolant.
will have to wait for the pics, as i'm leaving for down south today, n heaps to do ;)
dont supose u can get me 1 of the cranks out of the 2.4L :D.

the boost control solenoid, if just left unpluged should act as a strait through i beleive, try this 1st watch boost closely if it goes more then 5 psi, then u will need to connect the lower left line in that pic to the top right, the top left is the return boost line, it's the intake side of the turbo.

[InsaneAsylum]

your c20sel is controlled by bosch.... very intersting

our c20sel (and c22sel) is controlled by siemes simtec 56.5

[Lt Ketch]

simtec

SUCKS

[InsaneAsylum]

simtec

SUCKS

they really had grandparents and soccer mums in mind when they designed the vectra :D

[Iran]

Some News

:)

http://img527.imageshack.us/img527/5909/dsc08585so9cm2.jpg

It is only one perspective of as it goes to be!

Correcting what I had said, the C20SEL has water cooling in the trottle body!

[InsaneAsylum]

that looks fantastic!! really hard to tell that it's not a Z20let.... how does it perform?

[auzvectra]

except for the heat sheild, and the sump breather hose next to it ;).

[auzvectra]

oh, and i dont think it's water cooling by the way, it runs coiolanmt thru there, which would heat it up.

[astralopiteco]

that looks fantastic!! really hard to tell that it's not a Z20let.... how does it perform?

The project has not yet been completed, as a few parts are still to be delivered to him in Brazil. As you may notice from the photo, the turbocharger has not yet been fitted.:rolleyes:


3) The connections of the water feed and return pipes to the turbocharger and the locations were the water is collected and returned to. As above, if someone could post some pics it would be a great help.

This item is still an issue. Can anyone help? :confused:

[auzvectra]

i have seen the X20XEV up close but there should be a coolant return line from the top of the thermostat housing, about a 3/8 line, tap into this line for the feed and return, just re-route it thru the turbo ;).
this is basically how the setup is on the sri-t's.

oh and to correct what was previously said, the 2 grub screws on the rear are both for the oil!!!
1 is used for oil supply for the turbo, the 1 at 90 deg to the block and nearer the front, and the other (the 1 angled down) is used along with 1 behind the water pump, and directly behind that 1 on the rear of the motor, to get access to clean out the oil galleries.

[auzvectra]

i just looked at the pic abouve :).
the hose that is just above the dipstick in the pic, and runs accross the top of the exhaust is the 1 u want ;).

[OPC]

Hey Iran... great to see the parts i gave ya have gone to good use

seems just yesterday that Gustav was telling me about ur project

anyway good luck with the rest of the job

[InsaneAsylum]

The project has not yet been completed, as a few parts are still to be delivered to him in Brazil. As you may notice from the photo, the turbocharger has not yet been fitted.:rolleyes:



This item is still an issue. Can anyone help? :confused:

what are you talking about? the turbocharger is right there next to the 710 cap

... and the falangies

[blueraven]

except for the heat sheild, and the sump breather hose next to it ;).

and the throttle 'cable', the power steering reservior, lack of fuse boxes and a few hoses :P :)

good project, if anyone in australia wants to have a go, i have 95% of the parts you will need, going cheap :)

[poita]

would love to nik, dont tempt me you bastard

[auzvectra]

yeah i noticed the cable after, but figured that was enough ;).
maybe i should scan the pic for more items :).

[blueraven]

dooooo eeet poita :D:D:D

[astralopiteco]

what are you talking about? the turbocharger is right there next to the 710 cap

... and the falangies

No it is not...:p You will notice that the pipe that lies on top of the engine, connecting the air box to the turbocharger, is not connected to anything on its lower end. It is a really tricky picture, though!:rolleyes:

[astralopiteco]

and the throttle 'cable', the power steering reservior, lack of fuse boxes and a few hoses :P :)

Not to mention the MAF sensor that is there just to fill the gap between the pipes, as the Motronic 5.5 managing the brazilian X20XEV uses MAP sensor.:)


good project, if anyone in australia wants to have a go, i have 95% of the parts you will need, going cheap :)

Yep, Iran almost got them. But then, he decided to go for the VXR parts instead of the SRi-T. :cool: :eek:

[InsaneAsylum]

Not to mention the MAF sensor that is there just to fill the gap between the pipes, as the Motronic 5.5 managing in the brazilian X20XEV uses MAP sensor.:)

i'm sure the falangies fill the gap between the pipe.

isn't the multiple-antroscopic-filter used with the moronic 5.5 management?

[astralopiteco]

i'm sure the falangies fill the gap between the pipe.

isn't the multiple-antroscopic-filter used with the moronic 5.5 management?

As far as I know, it is used with the recent nVidia graphic cards!:p

[Iran]

that looks fantastic!! really hard to tell that it's not a Z20let.... how does it perform?

Thank you, but as the Piteco spokes the project is incomplet yet :( !


except for the heat sheild, and the sump breather hose next to it ;).

The heat sheild arrives yesterday! :D I purchased the heat shield (in steel) like this:

http://img215.imageshack.us/img215/4839/581bpk2.jpg


The project has not yet been completed, as a few parts are still to be delivered to him in Brazil. As you may notice from the photo, the turbocharger has not yet been fitted.:rolleyes:
This item is still an issue. Can anyone help? :confused:

The water return pipe is ok! But where I have to link it in turbocharger still is unknown :confused:

http://img261.imageshack.us/img261/4748/dsc08158vo5.jpg


i have seen the X20XEV up close but there should be a coolant return line from the top of the thermostat housing, about a 3/8 line, tap into this line for the feed and return, just re-route it thru the turbo ;).
this is basically how the setup is on the sri-t's.


I saw the water line in any photos of Z20LET and it seems that leaves from above the radiator to feed the turbocharger. It's not clear.



oh and to correct what was previously said, the 2 grub screws on the rear are both for the oil!!!
1 is used for oil supply for the turbo, the 1 at 90 deg to the block and nearer the front, and the other (the 1 angled down) is used along with 1 behind the water pump, and directly behind that 1 on the rear of the motor, to get access to clean out the oil galleries.

You say about the grub screws in turbocharger, right?! 1 that used for oil supply is the more to the center of tubocharger? Thank you!


Hey Iran... great to see the parts i gave ya have gone to good use seems just yesterday that Gustav was telling me about ur project anyway good luck with the rest of the job

Jason!!! You doesn't make idea of how much made somebody happy!!! :dance: Finally, my dream will come true!!! Thanks a lot! :D


and the throttle 'cable', the power steering reservior, lack of fuse boxes and a few hoses :P :)
good project, if anyone in australia wants to have a go, i have 95% of the parts you will need, going cheap :)

If you have the water and oil pipes of the turbocharger, we can make business! hehehe



Yep, Iran almost got them. But then, he decided to go for the VXR parts instead of the SRi-T. :cool: :eek:

:angel: :rolleyes:

Thank you Piteco!!!

[InsaneAsylum]

i don't think the water inlet or outlet will matter much... in my opinion, it's not like the oil that needs to use gravity to find its way back to the sump.

remember that the cooling system in a car is under pressure so the water will find it's way through a small hose quite easily.


hurry up iran.... we're all waiting!!! :D ;)

[Iran]

i don't think the water inlet or outlet will matter much... in my opinion, it's not like the oil that needs to use gravity to find its way back to the sump.

remember that the cooling system in a car is under pressure so the water will find it's way through a small hose quite easily.

hurry up iran.... we're all waiting!!! :D ;)

I even agree with your opinion!!! :angel:

But I need to know where I find the water line appropriate to feed the turbocharger! :rolleyes: hehehehe

InsaneAsylum be cool :angel: , in two months I'll post here the performance! :dance:

[auzvectra]

sorry the grub screws are on the back of the block for tyhe oil feed.
the water flow is irrelevant, either way doesnt matter.
yes the astra feeds coolant from the top of the radiator, even looks to be the hot side of the radiator, if you wish to do it this way, make a coupling to go into the lower radiator pipe for the feed, otherwise use the 1 from the thrmostat housing.
although when considering this in detail, that line is basically for the return pressure while the thermostat is closed, so i'm not sure how it would affect things if it was retricted, although there is little to no restriction on the coolant side of the turbo, so this may be no issue.

[Iran]

That's ok! The oil line is right now! I'll make a coupling to go into the lower radiator (distribuitor hose) for the turbocharger feed ! I purchased a water assist electric pump to works together, in coolant return! Then, the pressure fall doesn't will affect the refrigeration!

Thank you again!

[astralopiteco]

Guys, Iran just told me that the project has been completed!!

http://img403.imageshack.us/img403/8551/1dia0xh7.th.jpg (http://img403.imageshack.us/my.php?image=1dia0xh7.jpg)http://img211.imageshack.us/img211/7728/1dia1rf0.th.jpg (http://img211.imageshack.us/my.php?image=1dia1rf0.jpg)http://img222.imageshack.us/img222/2172/1dia2qk3.th.jpg (http://img222.imageshack.us/my.php?image=1dia2qk3.jpg)http://img403.imageshack.us/img403/3152/1dia3gu9.th.jpg (http://img403.imageshack.us/my.php?image=1dia3gu9.jpg)
http://img222.imageshack.us/img222/7941/1dia4jg5.th.jpg (http://img222.imageshack.us/my.php?image=1dia4jg5.jpg)http://img211.imageshack.us/img211/7657/1dia5cz1.th.jpg (http://img211.imageshack.us/my.php?image=1dia5cz1.jpg)http://img222.imageshack.us/img222/2606/1dia6ci0.th.jpg (http://img222.imageshack.us/my.php?image=1dia6ci0.jpg)http://img403.imageshack.us/img403/9497/1dia7wt4.th.jpg (http://img403.imageshack.us/my.php?image=1dia7wt4.jpg)
http://img403.imageshack.us/img403/6567/1dia8zc5.th.jpg (http://img403.imageshack.us/my.php?image=1dia8zc5.jpg)http://img222.imageshack.us/img222/3879/1dia9zj1.th.jpg (http://img222.imageshack.us/my.php?image=1dia9zj1.jpg)http://img222.imageshack.us/img222/9685/1dia11dj4.th.jpg (http://img222.imageshack.us/my.php?image=1dia11dj4.jpg)http://img222.imageshack.us/img222/8845/1dia12lw6.th.jpg (http://img222.imageshack.us/my.php?image=1dia12lw6.jpg)
http://img211.imageshack.us/img211/7101/1dia13tv2.th.jpg (http://img211.imageshack.us/my.php?image=1dia13tv2.jpg)http://img222.imageshack.us/img222/9717/1dia14xj6.th.jpg (http://img222.imageshack.us/my.php?image=1dia14xj6.jpg)

http://img235.imageshack.us/img235/7581/finalkj7.th.jpg (http://img235.imageshack.us/my.php?image=finalkj7.jpg)



Thanks everybody, for all your help. As soon as I get more photos and information on the assembly, I'll post here.

[auzvectra]

good to see, now you can buy an intercooler kit off me :p.

[OPC]

he's already got one and it cost nothing :)

well done iran lets just hope she has no gremlins

[auzvectra]

but thats a stockie :p.

[Iran]

Thank you guys!!! :clap:

You have a friend here in the Brazil, forever!

Best regards!!! :D

[OPC]

but thats a stockie :p.

and it cost nothing:p.

[Iran]

:)

http://img152.imageshack.us/img152/7532/vxr034ig1.jpg