1.6 8v Turbo Help.

[MrSilicone]

After some help from those who have built a 1.6 8v Turbo and know whats involved...
Basically so far the story goes....

I have a courtney turbo kit that i managed to source through ebay a little while back, and have just had my gsi engine re-built.

Thing is it doesnt have any instructions, i can work out the majority of where bits and pieces go, but then ill get stuck, on things like 5th Injector? does the sump need modifing? wiring loom? etc etc..

Was wondering if anyone would be able to supply me a write up on what you did, what parts the kit comes with and if poss some pics...

This might be a little too much to ask for but any help would be greatly appriciated. As courtenay were most un-helpful!!

Thanks
Mark.

[Mike]

Ok, basically the Courtenay kit is a very OTT kit with a lot of parts that are not needed!

5th injector - Not needed unless your planning on mega boost

Wiring loom - If your not using a 5th injector, you dont need to touch the loom.

Sump - Modified, yes. The oil out the charger needs somewhere to return to. Must return to the lowest part of the engine (obviously) so sump is the way foward.

Dont worry up the charger ends up sitting lower then the sump, you CAN get 12v pumps specifcally made to get around this problem (ideal for TT conversions - something ill be venturing into within the next 2 years)

[craig green]

Have you got an E16SE or C16SE.

Courtenay used the 5th injector on the cat'd C16Se as its not capable of adding the extra fuel, but the E16Se can do this if its tricked into it with a pressure switch wired into the TPS.

[MrSilicone]

Ive checked and the engine is a E16se, i take it from that its actually a GTE engine??

Obv thats good news with regards to the 5th injector nonsense? correct?

What would be the easiest way of modding the sump? whats the sump made from? could i weld onto it?

Sorry for the stupid questions, Bodywork is my specialised area!

[Mike]

Sump on a E16 GTE motor is steel, so yes, its weldable for DIY'ers.

Sump - Oil return pipe needs welding onto it, you need to weld a return pipe at the very highest part of the sump (I.E. Just under the sump gasket)

5th Injector - Fcuk it off, its not needed unless running mass boost, which the 1600 wont take well.

My 1.6T (albeit partially built) useless Sierra/Escort Cosworth oil pipes, SAAB charger & R5 GTT exhaust elbow/downpipe.

[chimp007_uk]

buy this and swap the parts and sell your kit on ;)

http://www.pngclub.com/forum/showthread.php?t=107867&page=5

[Mike]

^ i know the guy that build that, for £1k its a fooking bargain!!! I know how much work went into it, and what it cost him!!!

[chimp007_uk]

you're right it is a proper bargain just for the parts... I know the shell has a couple of dings, but when it was £1500 it was a bargain.

Shame I'm a NA man unless it comes to derv lol

[Mike]

Well, its got a Spax krpyton suspension kit, all new copper brake lines, resprayed, white leather retrim, the turbo manifold cost Chris about £500, the header & breather tanks were hand made for him by Sev's, the engines had a mahooosive rebuild, the wheels were brand new etc etc

IMHO the engine in it would fetch about £800 on eBay. Ive been offered £1250 for mine once its built (the engine not car)!!

[chimp007_uk]

true...if only i had the space lol...

i think my parent swould chuck me out with another car on the drive, got 5 as it is :(

wonder if he'll swap for a manta lol

[1.6 8v turbo nova]

lol id love a manta but i've already got a car :)

[MrSilicone]

nothing like spam!

I was actually after some technical help?