Swiss Trackday Nova

Hi There!

I've been busy lately and i got some spare time so.. let the writing begin :d

Because you can get in very big trouble for not having a catalytic converter under your car in switzerland (loosing your driving licence and so on) and i wanted to improve the exhaust system i decided to switch to a cheap and hopefully little more effective solution.

I wanted to replace the original cat...
http://i260.photobucket.com/albums/i.../IMG_7364c.jpg

..with a C20XE cat.
http://i260.photobucket.com/albums/i.../IMG_7372c.jpg

Therefore i had to cut the exsiting Manifold in pieces.
http://i260.photobucket.com/albums/i.../IMG_7376c.jpg

some adjustments with the "new" cat.
http://i260.photobucket.com/albums/i.../IMG_7379c.jpg

made a new pipe for mounting after the catalytic converter with a much bigger diameter :cool:
http://i260.photobucket.com/albums/i.../IMG_7382c.jpg

welded everthing that had to be welded and monuted it to the car
http://i260.photobucket.com/albums/i.../IMG_7396c.jpg

http://i260.photobucket.com/albums/i.../IMG_7400c.jpg

unfortunately it didn't make a big difference... at least i tried :roll:

Then i started to make the mountig points for the CV-Joint Suspension.
I tested if it would have been possible to weld the mountings vertically but that wouldn't work because the angle for the tie bars was bigger than it would allow.

...so horizontal it is!
http://i260.photobucket.com/albums/i.../IMG_7421c.jpg

before welding
http://i260.photobucket.com/albums/i.../IMG_7425c.jpg

and after
http://i260.photobucket.com/albums/i.../IMG_7433c.jpg

POR15 for rust protection
http://i260.photobucket.com/albums/i.../IMG_7441c.jpg

Nice
http://i260.photobucket.com/albums/i.../IMG_7437c.jpg

Bought some second hand brake proportioning valves.
http://i260.photobucket.com/albums/i.../IMG_7445c.jpg

and a computer cable lol
http://i260.photobucket.com/albums/i.../IMG_7457c.jpg

After a couple of days i began to disassemble the enginebay..... one more time lol

still complete
http://i260.photobucket.com/albums/i.../IMG_7570c.jpg

Everything had to go... EGR, MAP Sensor, idle valve and so on
http://i260.photobucket.com/albums/i.../IMG_7572c.jpg

including the whole engine management
http://i260.photobucket.com/albums/i.../IMG_7574c.jpg

then had to change the camshafts
http://i260.photobucket.com/albums/i.../IMG_7580c.jpg

to 266° cams
http://i260.photobucket.com/albums/i.../IMG_7585c.jpg

while i was changing the cams i had a visitor from UPS :)

The writing on the parcel was promising
http://i260.photobucket.com/albums/i.../IMG_7581c.jpg

and the content even more. hehehe
http://i260.photobucket.com/albums/i.../IMG_7582c.jpg

Complete KMS van Kronenburg engine management
- ECU MP25
- Basic wiring loom for 4 cylinder
- 4 injectors 380ccm
- Bosch 4.9 wideband lambda sensor
- KMS air temperature sensor
- KMS throttle position sensor
- KMS ignition coil
http://i260.photobucket.com/albums/i.../IMG_7583c.jpg

380cc injector close up
http://i260.photobucket.com/albums/i.../IMG_7589c.jpg

the inner workings of the MP25 ECU with the connector for programming
http://i260.photobucket.com/albums/i.../IMG_7607c.jpg

there was a lot to do. every cable had to be connected by myself
http://i260.photobucket.com/albums/i.../IMG_7610c.jpg

in order to fit the ne injectors i had to modify the fuel rail a little bit
top original / bottom modified
http://i260.photobucket.com/albums/i.../IMG_7597c.jpg

with fitted injector loom. Very tight, but it works
http://i260.photobucket.com/albums/i.../IMG_7598c.jpg

had to cut the distance sleeves, because the KMS injectors were a bit shorter than the original injectors
http://i260.photobucket.com/albums/i.../IMG_7595c.jpg

then had to switch the TPS sensor vom passenger to drivers side.
http://i260.photobucket.com/albums/i.../IMG_7601c.jpg

fitting the loom
http://i260.photobucket.com/albums/i.../IMG_7600c.jpg

lambda sensor comparison
http://i260.photobucket.com/albums/i.../IMG_7602c.jpg

loom fitting nearly completed.
http://i260.photobucket.com/albums/i.../IMG_7605c.jpg

Nice work as always. On the tiebar brackets would you be better boxing the other side in too to match the bent side? I'm no expert but it sounds like it'd add a bit more strength

Hi, good choice with the kms and risse-motorsport and nice corsa. :)

Quote:

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On the tiebar brackets would you be better boxing the other side in too to match the bent side?

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i decided to make my own subframe wich connects the tiebar and tca's to stiffen everything a little bit more.

Quote:

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good choice with the kms and risse-motorsport and nice corsa. :)

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thanks... or in a more familiar language: Danke! :d i think it would be better for you to check my thread at corsaforum.de ;)

KMS is an excellent choice. A guy local to me sells loads of them and uses KMS in his own cars/on his own motorbikes to great effect.



And... it's Dutch! :thumb::thumb::thumb::thumb::thumb::thumb: ;)

Quote:

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Originally Posted by ExTrEmeOc

To the 30th anniversary of the Corsa A (Nova) all Corsas could park side by side.
http://i260.photobucket.com/albums/i.../IMG_7259c.jpg

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Any pics of the Spider and what looks like a Sprint-C TR(Saloon)?

@ novasport: Here you go http://www.streetridez.net/index.php...ew&picID=57191

I've been busy over the last few weeks so here are the results of what i was up to. :)

Because the camshaft sensor is no longer needed i grinded the reference points of. This would maybe reduce some mass that otherwise has to be moved..... unlikley i know lol
http://i260.photobucket.com/albums/i.../IMG_7611c.jpg

and mounted
http://i260.photobucket.com/albums/i.../IMG_7615c.jpg

The bracket for the throttle position sensor had to be slightly modified because it wasn't possible to put the plug on the TPS.
http://i260.photobucket.com/albums/i.../IMG_7616c.jpg

problem solved
http://i260.photobucket.com/albums/i.../IMG_7623c.jpg

To get a first impression what needed to be done i layed out some wires including a standard C16SEi loom which i needed to cut apart.
http://i260.photobucket.com/albums/i.../IMG_7625c.jpg

I had to reuse the fuel relay...
http://i260.photobucket.com/albums/i.../IMG_7627c.jpg

...and the connector for connecting to the standard nova loom.
http://i260.photobucket.com/albums/i.../IMG_7628c.jpg

joined them together including a piece of KMS loom
http://i260.photobucket.com/albums/i.../IMG_7629c.jpg

after some fiddling with the loom i managed to lay out the cables
http://i260.photobucket.com/albums/i.../IMG_7630c.jpg

to keep the water, oil, fuel or whatever out of the car i used the plug from the SEi loom.
http://i260.photobucket.com/albums/i.../IMG_7632c.jpg

and after some hours i had the right lenghts for all the cabels.
http://i260.photobucket.com/albums/i.../IMG_7633c.jpg

after that i had to fit the ECU connector, therefore i had to cut all the cables to the same length.
http://i260.photobucket.com/albums/i.../IMG_7638c.jpg

The KMS wiring diagram is very easy to understand (at least for me :tard:) so ist wasn't that difficult to wire everything up.
http://i260.photobucket.com/albums/i.../IMG_7642c.jpg

finished
http://i260.photobucket.com/albums/i.../IMG_7645c.jpg

two 'n half hours later i had myself a nice little engine loom :cool:
http://i260.photobucket.com/albums/i.../IMG_7649c.jpg