vstryker Posted June 17, 2016 Author Share Posted June 17, 2016 I've been away for work in the last 3 months and I'm glad to be working on the car again. Radtec Extreme radiator ordered along with the MBE 9A4 ecu. SBD says they will include a base map which is usually good to get it started. But since we bascially have the same motor, our generous forum member Sean sent me his map which I will try until I can get it on the dyno. Thanks Sean! Also received a few things from Bruce, and my surge tank setup is here as well. Prepping to pull the old motor out, I had the car on jack stands while I disconnected the exhaust, primaries, electical conectors including battery cables and grounds, coolant hoses. Next, drained the oil, transmission fluid and coolant. Continued by removing the old radiator & fan, disconnected clutch hose. I broke the speedo sensor & speedo gear while trying to carefully remove it. Took out steering column, fuel line, throttle cable, more hoses & connectors. With the engine being supported by the hoist, I removed engine and transmission mounts. Playing around with the angle, pushing & pulling here & there I was able to get the engine & tranny out in one piece. I will weigh the 2 engines & hope it's a 40-50 pound savings as others have mentioned. Link to comment Share on other sites More sharing options...
yellowss7 Posted June 17, 2016 Share Posted June 17, 2016 Hey Van, I just had Steve at SBD, do the Remote tuning on my car on Wednesday. The prior owner had installed some Cams from SBD when he upgraded and had the MBE 9A4 installed at that time too. There was some question as to whether my coolant issues were due to a head gasket or detonation. Chicken or Egg type question apparently, so I had the head pulled and gasket replaced and Steve reviewed the old map and had me update the software and install a new map. Then he spent some time testing to make sure everything worked prior to our dyno session this week. I'm headed to the track for the weekend and we will see how it goes. Good luck with your install and tuning. Let me know if you have any questions. Tom Link to comment Share on other sites More sharing options...
super7guy Posted June 18, 2016 Share Posted June 18, 2016 Did you get the weight of the duratec before install? also what is and is not included in that weight. thanks, Wayne Link to comment Share on other sites More sharing options...
TurboWood Posted June 18, 2016 Share Posted June 18, 2016 So, what are you going to do about the exhaust which exist the other side of the car? Looking great so far! Daniel Link to comment Share on other sites More sharing options...
vstryker Posted June 18, 2016 Author Share Posted June 18, 2016 I already have a used duratec header & exhaust system, I might reuse my old titanum ammo can if the setup is too loud. Obvisouly i need to cut a hole on the passenger side and cover up the old driver side hole, I was thinking with some sort of vent like the top of the hood? So, what are you going to do about the exhaust which exist the other side of the car? Looking great so far! Daniel Link to comment Share on other sites More sharing options...
vstryker Posted June 18, 2016 Author Share Posted June 18, 2016 Insulating it with heat reflective gold foil to bling up the engine bay a little. I also had to lengthen some wires in order to move it to the drivers side. I didn't want the hot exhaust headers to melt the wires on the passenger side. Here's after cleaning up the routing of the horn as well as placement of the external reservoirs. Ran into a problem though as I was looking at mating the new bell housing & tranny together. The new bell housing have female threads and so does the tranny. Looks like I have to cut and modify the tranny mounting holes so that I can either use allen head bolts from the tranny side or use studs & nuts. Either way, I'd have to cut & grind the ends of the tranny casting mounts off. The 2 bottom mounting holes look easy to do but the top 2 look too tight. Any ideas on how or what to use to cut/grind? Link to comment Share on other sites More sharing options...
TurboWood Posted June 19, 2016 Share Posted June 19, 2016 That's quite strange. I would have swore the bell housing had through holes. Regardless, I would suggest modifying the bell housing, not the transmission. Daniel Link to comment Share on other sites More sharing options...
vstryker Posted June 21, 2016 Author Share Posted June 21, 2016 I weighed both engines with the alternator, starter, and oil pan mounted. It did not include exhaust headers, flywheel, or any fluids, so basically the short block. And the verdict is.... Zetec 2.0 SVT : 255 pounds Duratec 2.3 CSR260: 220 pounds Zetec aluminum flywheel, clutch, pressure plate: 26 pounds (Stock flywheel alone is about 24 pounds) Duratec lightweight flywheel, clutch, pressure plate: 19 pounds So all in, I will be saving a little over 40 pounds which was as expected. Did you get the weight of the duratec before install? also what is and is not included in that weight. thanks, Wayne Link to comment Share on other sites More sharing options...
Kitcat Posted June 21, 2016 Share Posted June 21, 2016 Zetec SVT engines have become somewhat scarce, ditto parts. What are you doing with yours? Link to comment Share on other sites More sharing options...
super7guy Posted June 21, 2016 Share Posted June 21, 2016 thanks Van, I am surprised as when I weighed my long block zetec with lightened steel flywheel and clutch , no manifolds nor engine mounts, ready for install was 215 lbs. This agrees with racelinea value of 95 kg. Wayne Link to comment Share on other sites More sharing options...
TurboWood Posted June 22, 2016 Share Posted June 22, 2016 What does the 6spd weigh? The SPC 5spd I have weighs 74lbs (no fluids or shifter). My ecotec is almost as heavy as the Zetec despite the aluminum block. GM knows how to pack on the metal. Daniel Link to comment Share on other sites More sharing options...
vstryker Posted June 22, 2016 Author Share Posted June 22, 2016 I just weighed the Caterham 6 speed with no fluids and no shifter, 65 pounds. The whole case is all aluminum. Link to comment Share on other sites More sharing options...
TurboWood Posted June 22, 2016 Share Posted June 22, 2016 Wow, that is light. My 5spd is also all aluminum. My car is going to be a little plump...haha.:nopity: Link to comment Share on other sites More sharing options...
BruceBe Posted June 26, 2016 Share Posted June 26, 2016 There is no need to modify the gearbox mounting ears on the 6-speed, to mate it with the standard CSR bell-housing, which *always* has threaded inserts. Using correctly sized socket-head cap bolts, everything works. Cheers, -Bruce Link to comment Share on other sites More sharing options...
vstryker Posted June 27, 2016 Author Share Posted June 27, 2016 Unfortunately, it looks like i might have an older 6 speed main case as the 4 mounting points are not straight thru "ears" like the newer ones I've seen but they are instead a "boss" type: The good news is that I have modified the "boss" by cutting/drilling them into "ears"and now an allen head bolt will fit from transmisson ears to the the CSR bell housing. While at it, I I decided to tear down the tranny to clean, inspect and replace all the seals, bearings and maybe some syncros if need be. I will probably do a separate write up as it is a whole other job in itself. BruceBe said: There is no need to modify the gearbox mounting ears on the 6-speed, to mate it with the standard CSR bell-housing, which *always* has threaded inserts. Using correctly sized socket-head cap bolts, everything works. Cheers, -Bruce Link to comment Share on other sites More sharing options...
BruceBe Posted June 27, 2016 Share Posted June 27, 2016 vstryker said: Unfortunately, it looks like i might have an older 6 speed main case as the 4 mounting points are not straight thru "ears" like the newer ones I've seen but they are instead a "boss" type: http://i25.photobucket.com/albums/c87/vstryker/Cosworth Duratec Rebuild/20160616_104427_zpsxh7veewr.jpg The good news is that I have modified the "boss" by cutting/drilling them into "ears"and now an allen head bolt will fit from transmisson ears to the the CSR bell housing. Interesting - attached is a photo of a 6-speed case, circa 2005 -Bruce Link to comment Share on other sites More sharing options...
MichaelD Posted June 28, 2016 Share Posted June 28, 2016 new 6spd for sale http://www.pistonheads.com/classifieds/parts-and-plates/parts-and-accessories/caterham/brand-new-caterham-6-speed-gearbox/5640246?v=c Link to comment Share on other sites More sharing options...
vstryker Posted July 9, 2016 Author Share Posted July 9, 2016 The MONSTER ENGINE is finally in! With the transmission complete and all bolted back together, I bolted it up to the bell housing tank and engine. Using an engine hoist in the front and a jack on the bottom of the transmission as it was going in, it took a bit of adjustments before I could install the 2 engine mounts and rear tranny mount. It was a very tight fit with the 2.3L in a narrow S3 chassis but I'm very happy to report that it all fits. Link to comment Share on other sites More sharing options...
vstryker Posted July 9, 2016 Author Share Posted July 9, 2016 Now it was time to fill in the old exhaust hole on the left, and cut a new one on the right. Used the existing one as a template for the new one. Bought a piece of aluminum louvers on eBay, painted it, shaped it to the bottom contours of the body and riveted it. Here's the new exhaust hole with the manifolds mocked up. I was a bit nervous about cutting the big hole for the intake at first but starting with a small hole and working my way by enlarging it 0.5" at a time, it eventually came out looking pretty good. I was surprised how well it turned out by just using a 3" cutoff wheel with a smaller dremel. Finished off the edges with edge trimmer for a cleaner look. Here you can also see the old exhaust hole covered up. Link to comment Share on other sites More sharing options...
TurboWood Posted July 9, 2016 Share Posted July 9, 2016 Nicely done! Cutting holes in bodywork is one of my biggest fears. I've been putting off mounting the front fenders because it's related to the bodywork. Daniel Link to comment Share on other sites More sharing options...
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