E16SE turbo build

[comptoncj]

Right, well finally Ive got some bits together to start this little build. Havn't got a clue what car to put the engine in once its done, was going to put it in the convertible but I've fell in love with the weber noise again hehe. So, a few months back i bought a courtenay manifold, t25 turbo, spacer plate, forge dump valve and oil feed off of Edd :) , hopefully me engine should be coming tomorrow from Dan F which has already been used as a turbo before as it has the oil return in the sump and I should have a AFM and FSE FPR on the way. As for plans, first thing im going to do is get the engine on a stand and take the sump off, probs bung a set of new big end bearings in and paint the block up nicely. I was speaking to my college tutor who runs an evo 6 group A rally car and he was saying I should look into Aquamist water injection so I'm going to get researching that. Im going to couple the engine with an f15 box out of a corsa sport, hopefully it will take the grunt.

Heres a few pics of what Ive got to play with.

bottom end
http://i767.photobucket.com/albums/xx311/compton251/block.jpg
top end
http://i767.photobucket.com/albums/xx311/compton251/head.jpg
turbo and bits
http://i767.photobucket.com/albums/xx311/compton251/turbokit.jpg
loom
http://i767.photobucket.com/albums/xx311/compton251/1600bits4.jpg
ecu
http://i767.photobucket.com/albums/xx311/compton251/1600bits5.jpg

More pics to come :) untill next time...

[stevie78]

got a f15 in mine m8 and its round about 148bhp so it should take it

[comptoncj]

Kool you running standard managment?

[stevie78]

nope 40s and head work and a few other goodies

[Edd]

glad to see you're building it up now mate.

hope it all goes well.

[comptoncj]

glad to see you're building it up now mate.

hope it all goes well.

Cheers Edd, yeah i hope so too. I got that turbo twisted in the end :) lots of wd40 and a little persuasion device :P

[Rich]

and a little persuasion device :P

A hammer by any chance? lol

Looks good like these sort of builds, i was using a 1400 block with 1600 head to run a turbo but didnt have time/money to get it completed

[comptoncj]

A hammer by any chance? lol

Looks good like these sort of builds, i was using a 1400 block with 1600 head to run a turbo but didnt have time/money to get it completed

Well yeah a hammer :P and oh right, well I hope to get the engine done in a month or so, still gathering all the neccisary bits. I think its eventual home will be in the convertible, but until then I've got a corsa sport that engine-less and i might put it in there as I can use it on the works insurance :).

My college tutor said I probs wouldnt need to run a spacer if i run aquamist, I'm not sure though.

[Rich]

depends if you want it to last, i would run it with no plate just standard compression lol

Few people on here have done it and run them for a long time no problem!

[Count Vaux Alot]

As long as you are sensible with the boost there shouldn't be an issue with the comp ratio

[comptoncj]

hmm, well I've got the spacer plate so I may as well use it can't wait to start building it. lol

[nova josh]

is that not a bit of a small turbo ??

[comptoncj]

is that not a bit of a small turbo ??

Don't think so, alot of people have used t25 turbos doing this. Should work fine.

[Count Vaux Alot]

is that not a bit of a small turbo ??

No its a good size for the application actually.

[Edd]

IMO I would run the spacer plate chap, the engine will last a lot longer.

People that don't on a e16 se over fuel it to stop the bottom end frying, bad idea really.

If you use the pressure switch that Courtenay use on TPS it will be fine.

I will pm you the part number. you get it from rs electrics, bout a tenner.

Edd.

[comptoncj]

IMO I would run the spacer plate chap, the engine will last a lot longer.

People that don't on a e16 se over fuel it top stop the bottom end frying, bad idea really.

If you use the pressure switch that Courtenay use on TPS it will be fine.

I will pm you the part number. you get it from rs electrics, bout a tenner.

Edd.

You think i should run a 5th injector type set up on it? Yeah any helpful part numbers greatly appreciated :)

[Edd]

dont need a 5th injector at all, waste of money.

pressure switch has two spade connectors and a vacumn pipe, it will sense when its on boost and leave the injectors open to fuel it accordingly.

[comptoncj]

dont need a 5th injector at all, waste of money.

pressure switch has two spade connectors and a vacumn pipe, it will sense when its on boost and leave the injectors open to fuel it accordingly.

Oh right, do you wire that up to the injector part of the loom then? I know when my college tutor used to run a touring car he put resistors on the injector loom which gave them lotsa juice n flames lol.

[MattBrown]

Oh right, do you wire that up to the injector part of the loom then? I know when my college tutor used to run a touring car he put resistors on the injector loom which gave them lotsa juice n flames lol.


One of the best tricks in autograss thatlol

[comptoncj]

lol i was thinking of selling them to barry boys as a superchip :P

[Edd]

it goes inline on one of the wires on the tps, il have to dig out the diagram to be certain of which colour of wire it is.

sounds pikey, but its what Courtenay did when they did the conversions years ago.

[comptoncj]

Oh right I see, the tps sends a different signal to the injectors because of that switch?

[nova_niek]

IMO I would run the spacer plate chap, the engine will last a lot longer. People that don't on a e16 se over fuel it to stop the bottom end frying, bad idea really.

That's right - overfueling just washes the bores. Not a good idea.

Niek

[craig green]

Plus the ign timing, which you cant really play with, wont be such an issue with the lower comp/spacer plate.

[mikec123]

is that not a bit of a small turbo ??

A T25 will be perfect for a 1600 turbo conversion im running a T2 and thats fine, will keep an eye on this one:thumb: Good luck;)

[craig green]

Aye, the engine goes well enough with a small T2. That T25 is from a Rover 2.0 16v T16 engine, & they arent shy.

[mikec123]

[quote=craig green]Aye, the engine goes well enough with a small T2. That T25 is from a Rover 2.0 16v T16 engine, & they arent shy.[

I agree, i got 191bhp out of mine with a T2 almost at the magic 200bhp:cool:

[comptoncj]

Kool, I don't know what sorta power it will be, the torque will be interesting though :P

[Edd]

i reckon you will be looking at over 150 bhp

[mikec123]

Kool, I don't know what sorta power it will be, the torque will be interesting though :P

191bhp is with DTA management are you using a standard ecu? My torque was about the same as the bhp

[comptoncj]

Yeah plans are to use standard managment for a start, so anything near 150 bhp I'd be happy with. I might go for megasquirt at a later date, and im going to be running water injection too.

[mikec123]

With standard ecu i think you should make 150bhp, i was looking at the aquamist setup i know novaneil the guy who had my engine before was running it let me know what you find out about it:d

[comptoncj]

Ive done a bit of research, its triggered by a boost sensitive switch and lowers combustion temperatures the first kits about £300.

[mikec123]

Ive done a bit of research, its triggered by a boost sensitive switch and lowers combustion temperatures the first kits about £300.

Might be worth looking at getting. I noticed your sump has already got a return feed to it nice one. have you got an oil filter relocating kit yet?

[philthepill_389]

i run a 1.6 turbo motor and it took me months to get the set up right lack of information on the conversion. I cooked 4 pistons blew head gaskets the lot finally got them all sorted now and it goes well. I have a full water injection system to go on but to be honest it don't need it. i run 3.5 bar of fuel and 0.5 bar of boost on a spacer plate and a t2 turbo and all is fine fingers crossed. I would like to see this wiring diagram on this switch set up as i have a few switch's that came with the conversion. there is also a two spade set up that runs from back of tps but couldn't find any info on vac pipes and wiring to set it up

[comptoncj]

Nah not yet, I've found one I can use off of ebay I'l get that when the engines built up and in the car. Well the engine hasnt been delivered to me yet so I havnt seen it yet lol was supposed to come today but dan has been held up so it wont be here till wednesday now :(

[mikec123]

cool will keep an eye out for your thread if i can be of any help to you or the other way round just pm me:cool:

[comptoncj]

Nice one chap :)

[SpankeeVec]

Cool project mate 1.6 rocks

[comptoncj]

Cheers bud yeah Im looking forward to building it, think it will be a bit of a challenge but well worth it :)

[comptoncj]

Little update today, had a quick look at the wiring looms I've got to join up to make the engine run so I rekon I know what I'm doing now in that respect lol More updates to come as soon as the engine arrives and I'l take some pics of the rebuild :)

[luke1.4sr]

photos?

[comptoncj]

Photos to come when the engine arrives bud :) then the build properly takes off :)

[luke1.4sr]

sweet:cool:

[comptoncj]

Bit of an update, been buyin more bits hehe.

My AFM and fuel pressure regulator came friday (Cheers Craig Green) and I bought the polished loom cover that Edd had for sale. Still waiting for the engine to arrive though next thing on the list after next pay day will be the oil filter relocation kit. I've nearly got all the bits to get the car in and put the engine in once it arrives lol.

Pic of the AFM

http://i767.photobucket.com/albums/xx311/compton251/P150110_1800_01.jpg

Pic of FPR

http://i767.photobucket.com/albums/xx311/compton251/P150110_1800.jpg

Pic of loom cover

http://i767.photobucket.com/albums/xx311/compton251/polishedloomcover.jpg

That is all for now :)

[comptoncj]

Right suppose i should update this thread lol,,, the engine never materialised :( so i am on the look out for 1600 8 valve so i can get to building the engine up! was deciding what gear box to use as well, not so sure how an f13 is going to put up with the grunt from a turbo'd motor.

[Edd]

F13 will be fine

[comptoncj]

lol ok, theyre cheap anyway so it wont matter if it goes bang lol, plan is to find an engine and then find a car to put the engine in as im happy with the carb'd engine in the convertible and i think my A reg shell is passed it, could be welded up and resprayed but it needs alot of work.

[comptoncj]

Hmmm may have found an engine to rebuild for the project, only trouble is it has been sat outside for about 7 years lol might take the head off and see what its like inside, its been covered up so it may not be too bad! pics to follow lol

[novalovingned]

Hmmm may have found an engine to rebuild for the project, only trouble is it has been sat outside for about 7 years lol might take the head off and see what its like inside, its been covered up so it may not be too bad! pics to follow lol

Wouldnt worry about that mate. The 1600 8v i put in my A reg sat for about 2 years before i bought it, then a further 4 years in bits. Fired up first time lol It will be fine.

[comptoncj]

Been doing some mock ups today, Got the T25 onto the courtenay manifold (havn't got any gaskets at the moment but for mock up purposes it will do lol) mounted it to the 12st engine i had laying around outside. One problem I have is I need to twist the turbo housing to a suitable point for the boost pipe to run from turbo to intercooler, but where it needs to be there is no holes for the actuator to mount to the housing. Think I am going to have to modify the actuator bracket and drill and tap new holes for it.

Anyway heres a pic of the mock up lol


http://i767.photobucket.com/albums/xx311/compton251/P020510_1515.jpg

Then as i was cleaning some 20xe parts I thought i would clean some e16 parts too so in they went hehe.

http://i767.photobucket.com/albums/xx311/compton251/P020510_1552.jpg

Heres the engine I spoke about before bless it, Hopefully i will get it apart this week and see if its going to be up to the job. I've got a spare crank and a couple of pistons fingers crossed the rest is ok though.

http://i767.photobucket.com/albums/xx311/compton251/P020510_1341.jpg

Now.... Looking at my poor A reg shell doing nothing in need of some TLC i though hmmm yeah A reg turbo nova sounds pretty good :) It doesn't need too much work, well I welded the floor up 2 years ago and put a plate where the tie bar bolts onto the front panel. It needs front wings, doors, rear arches and i bit of welding to the battery tray and behind the passenger side strut top. And yes i will be binning the smoooootthhhhh bootlid lol.

http://i767.photobucket.com/albums/xx311/compton251/P020510_1553.jpg
http://i767.photobucket.com/albums/xx311/compton251/P020510_1553_02.jpg
http://i767.photobucket.com/albums/xx311/compton251/P020510_1554_02.jpg

Got a bit done today Also I spoke to the engine builder and he was saying kent cams can grind me a cam with more exhaust lift for the turbo application so i will be getting a price off him soon.

until next time :)

[craig green]

Courtenay fit a 90 deg, a tube/hose connector. then another 90 deg silicone hose to aim the turbo's route back up at the intercooler. Because of this layout & the TB being on the same side of the bay, a twin pass type intercooler makes the most sense. Ie outlet & inlet on same side.

[comptoncj]

Yeah I was thinking of an R5Gtt intercooler.

[craig green]

As for the cam aswell, you could have the overlap between the inlet lobes & inlet lobes reduced. This is a feature that helps n/a engines draw in the mixture at the end of the exhaust stroke, but on a turbo application, you could argue that boost will blow staright out the exhaust ports, wasting some power.

Best to get some advice from Kent perhaps. They ought to know the difference in spec between say An XR3i cam & one for an RS turbo. If you get me?

[comptoncj]

Yeah well I will have a chat to the engine builder next week and see what we come up with. He was also on about enlarging the combustion chamber to save using the head spacer and two gaskets so I may do that as well.

[craig green]

Heres what I had behind my grille, just mocking up & checking size etc in this pic. But I put it right up under the fr panel, the grille did fit.

http://i30.photobucket.com/albums/c323/turbocraig/NovaGSi-WIP_pics/Novabits4sale019.jpg

You could maybe mod the combustion chambers, but it depends if there is enough material in the upper area after you have removed it & then allowed for new seats to be cut in. That & possibly a light skim off the piston crowns could be a compromise.

I think I mentioned the other day that machining the pistons & then having them cryogenically treated, which is supposed to make the material super hard could work. Something I keep thinking of...

[comptoncj]

Oh right il see what he thinks, I was thinking of aiming for 8:1 CR or should i go a bit lower?

[craig green]

8's is in the right ballpark really.
A 'smaller' turbo with a CR a little 'higher' will be a far more driveable engine off boost & its spool up will be more instant.

[comptoncj]

I see, going to get a remote oil filter kit in the next couple of weeks as well, im going to clean the engine bay up on the shell so as soon as the engine is internally built up I can put it in the shell and start working out where to route all the pipes. Also going to sweet talk my dad into spraying it lol not sure what colour to go though.

[brucer]

tidy little project this, hope you get it going and it being reliable. will keep an eye out on this.

[comptoncj]

Cheers Yeah i hope so too, im going to invest in water injection for less of a chance of melt down lol

[Rickyb]

looks a good project if that 1600 lump youve got is no good drop me a pm as ive got one thatll be for sale soon.

[craig green]

I see, going to get a remote oil filter kit in the next couple of weeks as well,
Also going to sweet talk my dad into spraying it lol not sure what colour to go though.

I found a good company for MOCAL bits, speedflow, google them. I can see them being real handy with the pipework next time I fit my engine.

Do it an old 80's Vauxhall colour. Age related. :)

[comptoncj]

Cheers buddy I'l have a butchers, Colour wise I may go blue, my uncle always used to call it non-descript blue lol but Il have a look at what its proper name is lol

[comptoncj]

Just bought a R5Gtt exhaust elbow off the bay :) the list of parts needed is getting shorter hehe.

[craig green]

Cheers buddy I'l have a butchers, Colour wise I may go blue, my uncle always used to call it non-descript blue lol but Il have a look at what its proper name is lol

China Blue like Lynz's??

not Lynz's but ...

http://i30.photobucket.com/albums/c323/turbocraig/retro%20Novas%20PNG/b004.jpg

[comptoncj]

Dont think so, its slightly darker ive got a door to go on the car that is the colour I'm on about I will take a pic of it at some point.

[comptoncj]

Bit of an update, exhaust elbow came friday i will get that bolted on the turbo after work tomorrow, pics to follow :)

[saloonwoody]

less talkin more piccy...in ??

[comptoncj]

lol all in good time, pics tomorrow

[Sloth]

you mean nordic blue, aka pensioner blue...

[comptoncj]

Hmmm havnt updated for a while as ive just started a new job and the nova kind of went on the back burner had a quick mess around with it the other day and I have a potention turbo mounting problem. I was using a mock up 1200 engine for the purpose of setting where I want the turbo outlet to go and now I have a problem with the actuator. As it stands the turbo outlet is pointing where I want it to but now the actuator pipe nipple is against the charger housing :S and its fixed to its mount so i cant turn it. anyone have any ideas? Il post some pics up of what i mean when i get a chance :)