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Author: Subject: Z20LET into a Haynes Roadster
Ben_Copeland

posted on 3/1/14 at 11:04 AM Reply With Quote
Z20LET into a Haynes Roadster

Its time i posted up my build diary for fitting my Astra turbo engine into my Haynes Roadster, seems to be one of the next upgrades people might start doing.

Firstly it started out with a NA 2.0 16V Vauxhall Engine C20XE so the conversion is a little easier for me. The Z20LET is a 2.0 16V Turbo engine, very similar to the C20LET which is the Turbo verson of the C20XE. This all means that the existing bellhousing and engine mounts all fit straight on, although the passenger side mount needs modifying for the boost pipe to go through.

Picked up a running engine and stripped stripping it all of bits i wont need anymore....

Picked up
Picked up

Z20LET Engine Before
Z20LET Engine Before

Cambelt
Cambelt

Its very busy this end and i dont like it !

Description
Description

Thats better.

Next i need to replace the throttle body, the TB on the Z20LET is fly-by-wire and i cant run that on MS2 (or cant be bothered to work out how)
Throttle Body Removed
Throttle Body Removed


I've bought a throttle body of a X20XEV which is effectively a NA version of my engine (2.0L 16v from a vectra/astra etc)
Its fits straight on and converts to cable throttle, its slightly larger which cant be a bad thing.
New Throttle Body Fitted
New Throttle Body Fitted

I actually ended up turning this round 180 degrees so it fits better.
Throttle Body
Throttle Body


[Edited on 3/1/14 by Ben_Copeland]





Ben

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Z20LET Astra Turbo, into a Haynes Roadster

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beaver34

posted on 3/1/14 at 11:05 AM Reply With Quote
looks fun,

turbo 7 cars are great fun

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Ben_Copeland

posted on 3/1/14 at 11:25 AM Reply With Quote
Next is to remove the sump which is massive and isnt going to fit, also i removed the balance shafts that are mounted over the crank. These sap power and also add a massive weight to the bottom of the engine. Unfortunately they are oil feed from the crank bearing caps, so they need tapping and filling so the oil doesnt come out !

Sump Off
Sump Off


Tapping Oil Feeds
Tapping Oil Feeds

Tapped and grub screwed.

Grub Screws in
Grub Screws in


Balance Shafts Removed
Balance Shafts Removed

Caps back in.

The downside of removing the balance shafts is they also act as crank girdle so you either need to find a X20XEV crank girdle that doesnt have balance shafts (early one maybe) or make your own.

Friend of mine sent me this to play with as it didnt fit with his sump....
Crank Girdle
Crank Girdle


Unfortunately i ended up having to cut it up as it didnt fit with my sump either, but strips are better than nothing.
Windage
Windage

I used the XE windage tray just cutting holes where the girdle stuck through.

I'm fitting a Caterham Alloy Sump from my XE engine, which just fits but ive had to modify the pickup pipe, using the head of the XE one with the oil pump end from the ZLET engine. Its a bit of a faff to sort and unfortunately i didnt take a picture, but just make sure its got no leaks! I also had to drill out the sump bolt holes because they are m8 instead of m6 like the XE, but easy enough to do.





Ben

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Z20LET Astra Turbo, into a Haynes Roadster

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Ben_Copeland

posted on 3/1/14 at 11:39 AM Reply With Quote
I then started checking over the turbo. It had been fitted with a VXR turbo and wastegate which is a popular power upgrade, pretty much a direct swap and good for about 300bhp.

I had noticed the oil feed pipe was oily and one of the connections was at an angle..
Oil Line
Oil Line

Dumb Arse!!!

Took it apart and luckily i rescued it with a small file and a bit of patience....
Oil Line
Oil Line

Better.

I took the exhaust manifold off to replace the gasket and found 2 stripped threads in the head and rusted studs/nuts
They'll all need replacing before the turbo manifold can go back on... BALLS.
Exhaust studs
Exhaust studs


I helicoiled the 2 threads in the head and replaced all the studs. While the exhaust manifold was off i painted the block black to get rid of the Red as it didnt match which my cars colours.
Painted Black
Painted Black


Also the turbo return pipe was held in with a bolt and self tapping screw and glue. WTF, how difficult would it of been to find another bolt for it. Again, luckily! i managed to remove the glue and cleaned up the bolt hole. Replaced the gaskets and bolted it all back up.
Oil Return
Oil Return


I also binned the dump valve bits and fitted a nice alloy recirculation valve, back to standard...ish.
Recirculation Valve
Recirculation Valve






Ben

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Z20LET Astra Turbo, into a Haynes Roadster

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maccmike

posted on 3/1/14 at 11:47 AM Reply With Quote
nice work keep the photos coming
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Ben_Copeland

posted on 3/1/14 at 12:01 PM Reply With Quote
Moved back over to the inlet side and decided to check the injectors. As i thought standard, and not suitable for VXR turbo power.

I had some Rover 800 Turbo injectors lurking in the garage which are a direct swap, a lot more cc's. So i sent them off to Mr Injector to get them cleaned and check etc.
380cc i believe @ 3 bar
Injectors
Injectors


Refitted the rail. Done

[Edited on 3/1/14 by Ben_Copeland]





Ben

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Z20LET Astra Turbo, into a Haynes Roadster

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Ben_Copeland

posted on 3/1/14 at 12:12 PM Reply With Quote
Got a bit of a painting bug from doing the engine block so decided to do the camcover.

Rubbed down
Paint Prep
Paint Prep


Primed with a etch primer
Primed
Primed


Undercoated white
Primed
Primed


Top coated with DynaRod orange and then lacquered to make it oil/petrol/heat resistant.
Painted
Painted


Didnt like the standard yellow oil cap, so rubbed that down and painted it black.
Painted Black
Painted Black


Also painted the bolts black too ;-)
Camcover finished
Camcover finished


Fitted and finished with a Black VXR spark plug cover.





Ben

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Z20LET Astra Turbo, into a Haynes Roadster

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Ben_Copeland

posted on 3/1/14 at 12:23 PM Reply With Quote
Time to strip the old engine out of my car. Ive done this a couple of times so should be easy enough.

Fully assembled car including nosecone etc.
Engine Coming Out
Engine Coming Out

Ok no nosecone in this picture...

To engine out on the bench in 1hr 15mins... not bad for an evening after work.
Engine Out in 1Hour 15mins
Engine Out in 1Hour 15mins


New engine hanging ready to go in.
Hanging
Hanging


Engine in and bolted up to the gearbox. Driver side engine mount in and bolted up. Just need to modify the passenger mount to allow the bottom boost pipe to pass through it.
IN
IN


Forgot to say: the clutch is ford galaxy 2.8 friction and Vauxhall pressure plate. Using alloy bellhousing and type 9 box

Jumped forwards a bit to fitting the radiator and intercooler.
Intercooler
Intercooler


Next i made up some mountings for the fans, i couldnt get one big fan into the space behind the radiator so went for 2 smaller ones instead.
Double Fans
Double Fans


Radiator is a Honda Civic alloy racing one i bought off ebay and intercooler is a universal alloy one from ebay. Both cost about 75 each

[Edited on 3/1/14 by Ben_Copeland]





Ben

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Z20LET Astra Turbo, into a Haynes Roadster

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swanntech

posted on 3/1/14 at 07:46 PM Reply With Quote
Hi ben just fitting an xe engine to my roadster i am useing a metal yukspeed sump is it necessary to fit a windage tray as i dont have one in my xe powerd grasstrack car
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Ben_Copeland

posted on 3/1/14 at 07:59 PM Reply With Quote
Needed to change the Inlet Temperature Sensor, but couldn't find one that bolted straight into the manifold, so i had to buy an adapter and tap that so the sensor could fit inside.
Air Temperature Sender
Air Temperature Sender


Went to refit the steering column extension, but it fouls slightly on the inlet manifold so i've had to put an extra joint in and rosejoint to support it.
Steering Column
Steering Column

Still waiting on some nuts to fit it in place.

Next up is the alternator bracket, its one i made for the XE engine so ive reused it and it bolts up in the same place just needed spacing off the engine slightly as it fouled on the cambelt cover.
The adjuster is made from 2 rosejoints, one right hand and one left hand thread with matching threaded bosses welded together with a nut between them. Picture speaks a thousand words...
Alternator Mount
Alternator Mount


Next i managed to source a belt and new pulley for the alternator that matched the crank pulley.
Belt and Pulley On
Belt and Pulley On


Bought some silicone hose and joiners just before xmas and so i started fitting it all. Got a big list of pipework and connectors that i still need to get, but its nearly there.
PipeWork!
PipeWork!


I've also started to tidy up the wiring and using all the OEM connectors i can find.
Tidy Up
Tidy Up


[Edited on 3/1/14 by Ben_Copeland]





Ben

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Z20LET Astra Turbo, into a Haynes Roadster

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Ben_Copeland

posted on 3/1/14 at 08:00 PM Reply With Quote
quote:
Originally posted by swanntech
Hi ben just fitting an xe engine to my roadster i am useing a metal yukspeed sump is it necessary to fit a windage tray as i dont have one in my xe powerd grasstrack car


You should do, but a friend of mine has that yukspeed sump and recons its ok without the tray.





Ben

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Z20LET Astra Turbo, into a Haynes Roadster

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swanntech

posted on 3/1/14 at 08:09 PM Reply With Quote
Thanks for that might try running it without first .nice looking engine your fitting. is the xe crank and main bearing caps the same as an let.
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Ben_Copeland

posted on 3/1/14 at 08:13 PM Reply With Quote
Bought a T piece pipe for the coolant system off ebay, but i was less than impressed considering it was quite expensive.

Crap T Pipe
Crap T Pipe

Crap T Pipe
Crap T Pipe


The pipe was all bent and the smaller pipe wasnt drilled out properly.

Connected the laptop up last night and started updating the basic map info to match my engine and i want to test the fans work etc.





Ben

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Z20LET Astra Turbo, into a Haynes Roadster

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Ben_Copeland

posted on 3/1/14 at 08:13 PM Reply With Quote
quote:
Originally posted by swanntech
Thanks for that might try running it without first .nice looking engine your fitting. is the xe crank and main bearing caps the same as an let.



C20LET yes, the Z20LET is different but not a lot.

I've got a XE bottom end all built up still if your interested

[Edited on 3/1/14 by Ben_Copeland]





Ben

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Z20LET Astra Turbo, into a Haynes Roadster

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Ben_Copeland

posted on 3/1/14 at 08:16 PM Reply With Quote
I'm also selling the Coscast Head atm on ebay and have a ton of spares if your after anything

http://www.ebay.co.uk/itm/331095959224?ssPageName=STRK:MESELX:IT&_trksid=p3984.m1555.l2649





Ben

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Z20LET Astra Turbo, into a Haynes Roadster

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Wheels244

posted on 3/1/14 at 08:29 PM Reply With Quote
quote:
Originally posted by Ben_Copeland
quote:
Originally posted by swanntech
Thanks for that might try running it without first .nice looking engine your fitting. is the xe crank and main bearing caps the same as an let.



C20LET yes, the Z20LET is different but not a lot.

I've got a XE bottom end all built up still if your interested

[Edited on 3/1/14 by Ben_Copeland]


Hi Ben

I thought you was flogging that to me ?

Good work on the install.

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loggyboy

posted on 3/1/14 at 10:47 PM Reply With Quote
quote:
Originally posted by Ben_Copeland
Bought a T piece pipe for the coolant system off ebay, but i was less than impressed considering it was quite expensive.

Crap T Pipe
Crap T Pipe

Crap T Pipe
Crap T Pipe


The pipe was all bent and the smaller pipe wasnt drilled out properly.

Connected the laptop up last night and started updating the basic map info to match my engine and i want to test the fans work etc.


Is that an ASH one?






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Ben_Copeland

posted on 3/1/14 at 11:02 PM Reply With Quote
quote:
Originally posted by loggyboy
quote:
Originally posted by Ben_Copeland
Bought a T piece pipe for the coolant system off ebay, but i was less than impressed considering it was quite expensive.

Crap T Pipe
Crap T Pipe

Crap T Pipe
Crap T Pipe


The pipe was all bent and the smaller pipe wasnt drilled out properly.

Connected the laptop up last night and started updating the basic map info to match my engine and i want to test the fans work etc.


Is that an ASH one?


No wish I'd seen the ash ones before I bought that crap.





Ben

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Z20LET Astra Turbo, into a Haynes Roadster

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Ben_Copeland

posted on 3/1/14 at 11:07 PM Reply With Quote
quote:
Originally posted by Wheels244

Hi Ben

I thought you was flogging that to me ?

Good work on the install.


Thought it was too much for you ;-)





Ben

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Z20LET Astra Turbo, into a Haynes Roadster

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yellowcab

posted on 4/1/14 at 11:18 AM Reply With Quote
Looking good Ben, good pics and diary showing your difficulties and how you overcome them, a good source of information for those other LCB readers to learn from.

Keep up the good work pal, should be a hoot to drive!

Looking forward to having a go already

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Ben_Copeland

posted on 4/1/14 at 05:42 PM Reply With Quote
Olz if you ever come and visit, we'll do a swap for the day ;-)





Ben

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Z20LET Astra Turbo, into a Haynes Roadster

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andywilson

posted on 4/1/14 at 07:35 PM Reply With Quote
good progress Ben, looking really good!

should be getting back on with mine in a month or so expect questions!

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Ben_Copeland

posted on 4/1/14 at 10:14 PM Reply With Quote
Cheers Andy

Modified the Rally Design pedal box to take a Vauxhall accelerator cable, had to add a small box to space up the cable sleeve and bend the back of the pedal up so the cable pulls further.
Pedal Box Modify
Pedal Box Modify


Decided while i was waiting for funds for more parts i'd flared the side panels to get some of the heat out!
Side Panel Flare
Side Panel Flare

Side Panel Flare
Side Panel Flare

Side Panel Flare
Side Panel Flare


Not much left i can do currently





Ben

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Z20LET Astra Turbo, into a Haynes Roadster

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Ben_Copeland

posted on 9/1/14 at 09:54 AM Reply With Quote
Ordered 300 worth of bits and pieces yesterday so when they come I'll post a picture of the bounty





Ben

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Z20LET Astra Turbo, into a Haynes Roadster

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Ben_Copeland

posted on 20/1/14 at 12:35 PM Reply With Quote
Sorry about no activity recently, my parts came in dibs and drabs so I didn't bother taking a picture. Still missing some bits which is annoying.

Anyway, I had a go at making an exhaust for the car. Tacked it all together and hopefully I can get it tig up later this week.

Exhaust
Exhaust


I also had to rejig the coolant lines off the back of the water pump because I found another pipe off the head, which is annoying as it means I cant fill it up with water till I get another t-piece.

Found Pipe
Found Pipe


That's it for now, i'll hopefully have all the bits by the weekend (except the extra t piece) and I can finish most of the pipework



[Edited on 20/1/14 by Ben_Copeland]





Ben

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Z20LET Astra Turbo, into a Haynes Roadster

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