Members Page/Marcell Gal/Engine Swap

MembersPage/MarcellGal/EngineSwap (2006-03-16 04:43:08)

Index for MembersPage/MarcellGal recent engine project

After fighting with cold weather, snow, fuel plumbing issues, unknown ignition module, misterious GND connections inside the unknown harness, damage due to static electricity, bad sparkplugs, bad injector connection, reverse information about VR sensor polarity, bad information about engine position, missing injector connection again (after small rewiring - this was quite stupid), mechanical problem with hood, weather (continuously), dyno, the engine is tuned, not just VE (that is damn easy and fast with lambda-target and incredible ego correction) but ignadv as well.

[ config.txt and tables.txt] after some tuning. Note that WBO2 hardware is special - experimental (my wbo2_nernstdc_target, wbo2_ri_target and wbo2_... PID settings will not work with a standard WBO2-controller setup)
[tables.txt] j[] smoothed after learning, because we didn't spend enough time at all loadsites for learning. This is the fastest way:learning shows the trend, and we have the final word.
MembersPage/MarcellGal/EngineSwap/TaskList - tasks checklist
MembersPage/MarcellGal/EngineSwap/ToolList - tools checklist
MembersPage/MarcellGal/EngineSwap/QuestForSpace - cannot fit the turbo
MembersPage/MarcellGal/EngineSwap/DaewooHarness - old harness
MembersPage/MarcellGal/EngineSwap/Wiring - wiring and pinout
MembersPage/MarcellGal/EngineSwap/VrTrigger - 60-2 crank trigger
MembersPage/MarcellGal/EngineSwap/Ignition
MembersPage/MarcellGal/EngineSwap/AirFeed
MembersPage/MarcellGal/EngineSwap/FuelFeed
MembersPage/MarcellGal/EngineSwap/StarterMotor
MembersPage/MarcellGal/EngineSwap/ElectronicProblemList

The preparations/brainstorming for this project is below - will be cleaned up some day.

cars

2001 year Opel (Vauxhall / GM) Astra 5door with 4cyl 1.6L 4cyl, 8valve X16SZR engine (Delco ECM, central injection, with 4-wire bipolar IdleControl/IdleValveStepper, charcoal canister, and EGR; no power-steering, no ABS), front wheel driven: available for project. I verified that the Delco ECM pinout I got from MembersPage/Fero matched the measurements I made myself before.
1998 year Honda Civic 5door with 4cyl 1.4L engine, front wheel driven, power-steering, ABS (not available for project). The only thing I like in this car is the suspension. I decided I will stay away from modifing Japanese cars.

Both with manual 5 speed transmission and air conditioner.

cars that currently are not available for my projects :-)

Collected parts

kkk03 turbo (good for appr. 190..220HP) with pneumatic wastegate
charge cooler (air-air). No idea of its performance
many electronics, including several GenBoard/VerThree
1.6L 16valve GM/Daewoo 106HP NA engine with harness and many. A bit heavy (100 kg?), closed deck engine. Already mounted mechanically in the Opel Astra

Constraints:

I have little time and chance to spend on the mechanical stuff, so I don't intend to invest too much money
I don't have my own mechanical workshop. See MembersPage/MarcellGal/WorkShop
I don't have a well defined purpose (racing, or 600 Hp or something). I'm thinking on 1.6 .. 2L engine with turbo and GenBoard/VerThree for a reliable and clean street-car. I also have some AutoTrans or sequential gearbox tweaking in mind, but that could cost much time - postponed for now.

8 or 16 valves - on 4cyl

I was warned that the 16V heads have most likely higher knock treshold than the 8V. Noone knows real numbers, but there can be some truth in this.

It was always clear that with 16V (and otherwise similar setup)

max torque is higher and
required boost lower
EBP slightly lower for same flow

Since top end power for a turbo is usually detonation limited, higher knock treshold also means more top-end power.

It seems I'll go with a 16V head (but same "small" 1.6L displacement). The 8-valver goes to rest (can be swapped back on a weekend if it's needed for some reason: eg. renovation of 16V engine or sales of the car).

I'm thinking of buying

Recently I found a nice Opel disassembly workshop nearby(Budapest, Csepel, RÃƒÂ¡kÃƒÂ³czi u. 185):

2L 8 valve opel engine (160 Euro)
1.8L 8valve opel engine (160 Euro), maybe I can barter with [TÃƒÂ³th Lajos (30) 5001295 - I could have as well found him when working for t-mobile] - he is also into high RPM NA engines, ITB InTake/DryManifold and some experience in metalcasting ( GenBoard/VerThree/CustomCNCCase in mind)
1.6L 16valve engine (almost brand new, 106 Hp NA from factory) for 160 Euro. This is better for economy, and registration won't cost anything (if I decide to make the swap official). 170 Hp with turbo should be enough for a 1020kg FWD car with not superstrong transmission. I bought this. Not in my hands yet. Lacking an own workshop, I have to ask my father to store a 70cm (max dimension :-) object for me :-) Or rather take to the exhaust shop if possible.
[Opel Vectra 4x4] with 2L 16V engine. Appr. 1040 Euro. Not streetable, but could make good spare parts (but questionable condition).
manual GearBox (for FWD opel) (80 Euro)
AutoTrans (for FWD opel) (200 Euro)

The guys say they were operable when the donor cars were disassembled. It's hard to be sure though, so there is always some risk (even if they were operable). They are mostly from German cars. Fortunately there is little variability with Opels. The GearBox is different for front and rear wheel, but almost that's all. The engine fixation is slightly different as well, but it is possible to play Lego. They are servicable relatively easily (compared to eg. a mazda323 nightmare servicability I've seen recently).

1996 year Chrysler Neon 4door 4cyl 2L (106kW, NA from factory) with manual 5-speed transmission and air conditioner. Little other extras (the air-conditioner is the only important "extra" for me), but for only 2150 Euro (suspiciously cheap compared to local prices...) 85000 miles in it. Looks like it is in good condition. Haven't checked paint-thickness. Can someone elaborate on this type of car? It seems like an economy-class US car.

The Neon is a fun FWD car. Easy to modify and tune. The bottom end of the 2.0 liter engine can handle 1-1.5 bar boost with out much tweaking. Economy in the US, on the large side of economy in Europe. Rooms four adults easily. It's a great car to drive in my opinion, nice and aggressive with the stock suspension. LOTS of after marked parts available. Important to check: That it runs and idles nice, capacity on the heater and that the AC works, paint, and the electrical wiring system. Overall a great car that people overlook. This also leads to low used car prices.

I just noticed the Neon is sold as Crysler and also as Dodge brand (not a frequent car in Budapest, Hungary).

Admittedly, a 4WD audi would make a better project car finally. But it might also be a good idea to start with something simple (and easily available) first, and migrate to a powerful (eg. 4WD V8 turbo :-) beast later.

local stuff

In Hungary it's not easy to swap engine legally, but a similar engine shouldn't cause too much problem.
A streetable 2L car costs about 400 Euros / year here if it runs 0 km. 1km is appr. 0.1 Euro (fuel) + amortisation.
The taxes are considerably higher over 2L displacement.
Also, an engine above 2L consumes much gasoline in city (I mostly drive in city). Remember that gasoline costs 2x more than in US because of taxes (which is nice, fossiles should be taxed heavily all over the world because this enforces better practices, like good logistics, telecommunications, and better environment protection: I know this is not a popular belief, it is just a scientific fact).

Strategy

Given the above circumstances, with an aim to just learn / play with engines:

DONE getting spare opel engine
engine storage: tougher than I thought. Heavy as hell.
optionally get spare FWD GearBox. Or do I need just the clutch?
decide about harness. The car is equipped with a harness for the Delco ECM. Not suitable for the 16V engine (not even with the factory ECM for the 16V engine) since GenBoard has more features that I want to utilize. I am biased towards getting 2 connectors that plug into the factory harness (eg. smashing a broken ECM) and wire to GenBoard to be as plugnplay as possible. I'll need a few extra wires and connectors, WBO2-connector and crimped-DSUB comes to mind. This way the factory harness would be untouched.
prepare the engine so it can be swapped in a weekend
keep the car operable most of the time, and the other engine ready to swap in should it be needed

Please raise any questions, recommendations, feel free to edit the text.

I just got a mail (actually waited for me since 20050105) about a pack from New Zealand, that I think Richb posted 8 WBO2 sensors in November. They want me to pay 25% VAT for it (but no customs duty, interestingly) - I will pay of course. This has been the first time this happened. Let me note: it took quite long to arrive, I pretty much forgot about it. Probably the customs were sitting on it during the xmas holidays. (we lost a valuable pack from US => HU sent out on 2004.Oct.25, but that's another story - there is some hope that would still turn up ?).

OPEL ECU connector hunt: delete in 2005 Feb. (Hungarian)

Szoval visszairt a srac akinek van egy rossz ECU-je:

Bereczk TamÃƒÂ¡s 06 30/9951 058

Hivd fel es beszelj vele!

Irt egy masik gyerek is, bemasolom a levelet, o nem adott telefonszamot meg, irj neki levelet szerintem es beszeljetek meg a dolgot!

Az aproNeten feladott hirdetesedre az alabbi valasz

erkezett:

> Keresek hibas ECU- t 2000- es OPEL astra 1. 6-

> oshoz. De mas autobol valo is jo, a lenyeg az

> hogy a csatlakozo az ECU- n ugyanolyan legyen!

> Hivj batran ha van valamid, az arban biztosan

> megegyezunk! A lenti linken van 1 kep a

> csatlakozorol.

Szia !

A rajz alapjÃƒÂ¡n ez egy Astra F ECU. Azt azonban mÃƒÂ©g tudnom kellene, hogy 16 szelepes vagy 8 szelepes motorrÃƒÂ³l van-e szÃƒÂ³. Ha ezeket az infÃƒÂ³kat megkapom tÃƒÂµled , akkor lehet hogy tudok segÃƒÂteni, mert nekem van egy kÃƒÂ©t rÃƒÂ©gi Opel ECU-m.

gearbox:

http://hirdetes.duen.hu/hirdetes.php?o=hir_resz&hirkod=4a244345658a86cea5e8075c2fa5a336&s=943