Hi there, I am new to this forum having been referred here from corsasport.com as you seem to be the daddies for all serious engine mods. My car is a 1998 1.6 16V sport with the ecotec engine and has done 29,000 miles. Engine wise it is standard at the moment. I was originally planning on getting a Manzel power box and later on a turbo, but after talking to a number of people I have decided to go for the SBD 164 kit. I would really like to fit the kit myself and have a few questions for anyone who has done it to a corsa.
1. Does the alternator and header tank have to be moved, I think I read somewhere that this is required for the bodies to fit. If so how do you do this.
2. Where do you fit the aftermarket ECU. Can you easily remove the motronic brain/ loom and fit the new one in its place or is the standard loom a nightmare to remove.
3. What sensors does the new ECU require i.e. lambda, cam, road speed etc. will the Vauxhall ones do or are others required.
4. How to you connect up the DIS module. I understand the SBD kit includes an ignition coil, how does this work
5. What is the situation regarding the cat and emissions for the MOT. I must be able to pass, as this is the only car I have and it needs to be roadworthy
6. did you find any pitfalls during the fitting e.g. special tools required or tight bolts which were difficult to remove.
7. Where to you get your insurance for a throttlebodied motor
I am just staring to save up for the conversion just now and it will probably be a year before I go to fit it (I will be 25 then and my insurance will be lower), However I am keen to know exactly what I need to do now, as I have never attempted anything this big before and don't want to make an expensive mess of it.
1. they stayed put on my installation, best wait till a corsa TBd person says tho
2. same place a the old ecu, or wherever you want
3. sensors are supplied or the loom just clips into the standard ones
4. DIS is an option on the MBE mapping, just order it with DIS enabled
5. emmisions are no problem, the engine actually runs quite lean at idle and off throttle
6. no special tools really, handy if you have a clue tho
7. cheaper than my old 8v was - 500 quid FC, but check your insurers or phone liverpool victoria (see other thread thats in chit chat at the mo)
You are not alone, although i have messed about modding my car here and there, never on a truly large scale.
Im also in the process of saving for the Ecotech 174 kit from SBD but decided it might be best to get them to do the work, although it depends on the cost of doing that. Any hiccups they can then iron out.
Im only able to answer your question 5, being something i looked into today too.
Apparently the kit comes with an optional (wide band) Lamda (think that spelt right) sensor, which along with the mods exceeds the manufatures own emissions standards, so the cat aspect isnt a concern. If your kit is like the one im getting, its not compatible with the standard cat and will mean its removal but you can opt for a sports cat to remain fully legal which is also compatible.
As far as im aware, (please correct me if im wrong), as long as a car is able to pass the emissions test, it matters not if a cat is there or not, although legally it should be there, but its unlikely that a copper will ever stop and ask to see it.
Some cat replacement pipes look like a cat is in place too.
Thanks for the replies guys, I am well up for getting this done but have had a few disasters in the past with modifying and don't want any this time. I am sure with the help of the guys on this board it will go OK......Hopefully
I believe on the 1.6 engine something to do with the alternator must be modified also, in order to provide clearance.
AndyH is your man - he's got that kit on his Corsa and knows the ins and out well no doubt.
Check with SBD that the DIS coil pack is compatible - I imagine it is - then you just need to make sure the loom you order is for dizzyless and it'll plug straight in.
The only sensor which you will need to get extra is an air temp sensor I think - I don't think your car has one. Another possibility is a throttle position sensor - I don't think the GM one can be used on throttle bodies.
don't fret though, SBD are well used to supplying tailored kits - it'll all be there in the box.
Hi AJ - the other questions have been well answered here so perhaps I can fill in one or two gaps for you.
Header tank - will have to be moved to allow clearance for the RHS trumpet. I moved mine to where the old airbox was, but I sometimes find the water doesn't circulate too well. Never given me any problems, but I shall be moving it to the other side - just forward of the battery. Mind you, I've ditched all the air con from mine, so don't how much room you'd have there.
Alternator - you need to move it back and down a couple of inches to clear the air filter over the trumpets - if yuo don't the LHS base plate of the air filter will catch on the alternator. Best way is to get someone to knock up a bracket.. On the other hand, if you intend using a smaller uprated race alternator, there should be adequate clearance.
Coil pack - I had my TBs fitted by Mark at Owen Developments. We had problems with the standard coil pack - you may want to check with him (01865 820580). I'm sure he wouldn't begrudge a couple of minutes of his time
CAT - the standard Corsa cat has the bore of a peashooter. If you want to retain it, you may have to accept that you'll get less than the advertised 164 horses.
Spend some money on SBD's manifold - really makes the most of everything. Be prepared to ditch air con though (and save 30kgs )
You are right to save up for TBs and not go down the Mantzel route (good as it is for the money). This engine is brilliant and there's almost no limit to how far you can take things (other than money!)
Thanks for the reply Andy, I have heard that you are the man to speak to regarding this. My car doesn't have aircon anyway so this shouldn't be a problem. I am not that bothered about keeping the cat (would rather ditch it in fact) but I must be able to pass the MOT as this is the only car I have and MUST be able to start and take me to work every day. Are the emissions low enough to pass the MOT without the CAT. How did you construct the modified alternator bracket. My car had an automatic drivebelt tensioner as I am sure yours does, so within limits tension should not be a problem but how did you get the bolt holes to line up. Are you using the standard header tank. I think I might get a smaller alloy one made up and try to keep it in the same position as standard with a modified mount. How is your car at staring in the winter. The only thing that slightly bothers me about the throttle body idea is that it might not start in the winter or idle well (no idle control valve). Have you had any bother with this. I stay in Scotland but wouldn't mind coming down to Cumbria sometime to see your car if that would be OK with you, as It would really help me to see the system installed in a similar car, as I am planning on fitting it myself if possible.
Hi Alan - OK, first things first. Properly set up with a decent ECU, an engine with TBs will start first time, everytime and with a few blips of the throttle, you'll be fine. I live high up in the Pennines and it's frigging freezing here in the winter - in 2 years have never had any probs. As for emissions, I run lumpy cams, so I can't pass my MOT even with a CAT let alone without a CAT. But you could fit either a high flow CAT or PM me about other ways around the problem. Let's just say my Corsa is fully road legal as far as MOT is concerned. I use a TAS small alloy header tank and am also using the original alternator bracket, as my filter sits up on the mouths of the trumpets - I've emailed you a pic of my engine bay. You're more than welcome to come down and see for yourself - I've had to learn the hard way as I've not found anyone else who's plumbed TBs into a Corsa. If I can help, I'd be more than happy to.