For anyone wanting a blow by blow (or part by part, or mistake by mistake) rendering of the installation, here is the original thread. http://www.sunbeamalpine.org/forum/showthread.php?t=9500&highlight=Duratec
Here are some pics of the "finished" (I don't think it will ever be truly finished) installation:
The mods to the engine are all bolt on. Did not even touch the ports.
The intake manifold was constructed to fit into the allotted space. Runners are 1 5/8" O.D. exhaust tubing, 19" long. The plenum is 3" tube, 10 1/2" long. The throttle body in the pictures is 50mm, which is smaller than the stock 2.3. It is too small, I'm in the process of adapting the stock unit to the intake.
The header is 1 5/8" O.D. tubing into a flat 4 collector, once again, made to fit the space available. Exhaust system is 2" with a generic turbo muffler followed by a generic glass pack. They work well for the street.
ECU is by RootesRacer. It controls ignition as well as fuel. Performance is above my expectations. For a baseline to performance, there is a hill in front of our house. A 5 speed ZX2 (published 0-60 times are 7 seconds) can start at the base of the hill and be doing 60 mph at the crest of the hill. That is balls to the walls, wide open driving, shifting at 6500 or so. The Alpine can be doing 70, starting in 2 nd gear and shifting to third in the 5000 range. I used a 2 nd gear start as the 2 nd gear synchronizer is shot and a quick 1-2 shift is impossible. The injectors are stock, 27 lb/hr and are currently running at 94% duty cycle at 7000 rpm, but the power is below 6000 and is a beast from 3000-5000.
The best part is yet to be attained. While tuning the engine this past fall, I was accelerating from 2,000 rpm to 7,000, up the hill in second gear while data logging. On a typical run, the computer would log 54-56 cells of info. Rarely, the engine would make the rear wheels squeal at about 2500 rpm and the run would take only 18 cells. I was not able to determine exactly what was causing the 66% reduction in time. As near as I could tell, the data for a normal run and the quick run were the same. I think I am running a little too lean.
Bill
Here are some pics of the "finished" (I don't think it will ever be truly finished) installation:
The mods to the engine are all bolt on. Did not even touch the ports.
The intake manifold was constructed to fit into the allotted space. Runners are 1 5/8" O.D. exhaust tubing, 19" long. The plenum is 3" tube, 10 1/2" long. The throttle body in the pictures is 50mm, which is smaller than the stock 2.3. It is too small, I'm in the process of adapting the stock unit to the intake.
The header is 1 5/8" O.D. tubing into a flat 4 collector, once again, made to fit the space available. Exhaust system is 2" with a generic turbo muffler followed by a generic glass pack. They work well for the street.
ECU is by RootesRacer. It controls ignition as well as fuel. Performance is above my expectations. For a baseline to performance, there is a hill in front of our house. A 5 speed ZX2 (published 0-60 times are 7 seconds) can start at the base of the hill and be doing 60 mph at the crest of the hill. That is balls to the walls, wide open driving, shifting at 6500 or so. The Alpine can be doing 70, starting in 2 nd gear and shifting to third in the 5000 range. I used a 2 nd gear start as the 2 nd gear synchronizer is shot and a quick 1-2 shift is impossible. The injectors are stock, 27 lb/hr and are currently running at 94% duty cycle at 7000 rpm, but the power is below 6000 and is a beast from 3000-5000.
The best part is yet to be attained. While tuning the engine this past fall, I was accelerating from 2,000 rpm to 7,000, up the hill in second gear while data logging. On a typical run, the computer would log 54-56 cells of info. Rarely, the engine would make the rear wheels squeal at about 2500 rpm and the run would take only 18 cells. I was not able to determine exactly what was causing the 66% reduction in time. As near as I could tell, the data for a normal run and the quick run were the same. I think I am running a little too lean.
Bill
