4. Engine/Performance history!
After 5 days of hard labor, (even still isn't done yet), here is first overview of this project.
1. Opel engine c20xe
2. Opel engine mount for kadett GSI
3. Opel engine mount absorber for kadett GSI
5. clutch set for c20xe
6. Opel Astra-G electrical hydraulic power steering
7. Daewoo Lanos Gearbox (D16)
8. Daewoo Lanos A/C komp
and everything else from Lanos
Everything Bolt on, except for A/C compressor, have some mounts remaking.
Here is first results:
And first test drive:
History of work in progress:
8.6.2006. Thursday. Morning in 8am, project has started. Unplugged all cables. Unplugged gear shifter. Unplluged gearbox. Removed axes and front wheels. Unplugged engine with gearbox, and lowered on the floor. The engine is out...
8.6.2006. Thursday. 12h. Engine is out. The new engine is relocated in the garage near the car. Now new engine is being worked on final things like paint job, and last details...
9.6.2006. Friday. Morning, 8am. I was getting a new clutch bearing. Connecting gearbox and engine. Everything is bolt on!!!! Clutch set is from c20xe, but it's lanos gearbox D16. ;)
9.6.2006. Friday, noon. I was getting electrical-hydraulic power steering pump from Astra-G, ready for installing in lanos. We were making mounts to mount it below left headlight. This is great spot for it...
9.6.2006. Friday, 4pm. Getting the c20xe engine inside. Everything BOLT ON!!!! This is great! Engine mount is for Opel Kadett-E gsi/astra mk2 for 2L engines. It fits perfect on lanos. :D ;)
10.6.2006. Saturday, 8am. It's a fuck up. A/C compressor mounts don't fit on engine halls. We had to make some mount reworking. But it's done...
10.6.2006. Saturday, noon. Mechanical part is done!
There were some minor issues with coolant bowels. exhaust pipe fitting, etc... No big deal.
10.5.2006. Saturday, noon. I was getting ready to wire it up. I had to rewire, every wire by wire. From Opel c20xe wire to Lanos instrument or other wire. Wire by wire. I have used ECU from c20xe, only. ECU from lanos is removed. c20xe ECU doesn't control coolant fans and A/C. This could be tricky...
10.5.2006. Saturday, 10pm. Still wiring some wires. I have wired electrical power steering pump. It works! Sounds like an airplane, but it works... :D
11.5.2006. Sunday, 8am. Still wiring some wires... :roll:
11.5.2006. Sunday, 4pm. Basic wires (engine management) connected. I will try to fire it up. ECU doesn't fire up gasoline pump... Damn. Output is dead. I will rewire fuel pump just for test. Firing up engine. It works!!!! Like a truck. But it works! :D
11.5.2006. Sunday, 10pm. Changing ECU. Firing up engine. It works on 4k rpm in neutral. Something is wrong. After some time of fucking with it, I have found an issue around throttle. :(
11.5.2006. Sunday, 11pm. It's done. First test drive! :cool: Damn. This is unreal. Gear shift isn't tuned well, clutch isn't tuned, but it loads every gear fast, and furious. The smile went on my face, and all the fuck ups were gone from my mind...
It gets to 120mph in no time. I had flame out of exhaust at the end of 4-th gear... Damn. This is great!
12.5.2006. Monday, 8am. Still doing some wiring. Coolant fans and A/C isn't connected yet. Accu is getting on my nerves. Alternator is to damn weak to power up accu, power steering and everything. I mustn't power down the engine, because then I have to ask other drivers to plug wire accus to power it up... Damn, this is annoying! :mad:
13.5.2006. Tuesday, 4pm. I have bought LPG agitator for inlet for c20xe. I have mount it up. Firing engine up on LPG. It works. Not steady, but it works.
14.5.2006. Wednesday. Did some more shopping. Tuned up clutch.
15.5.2006. Thursday, 8am. Working on TPS. It doesn't work right. Also, changing wires on alternator, starter, and accu. I have put new strong wires.
Did the work late at night. Voltage has raised from 12.6 to 13.6V. Test drive... Engine doesn't work well! :mad: :angry:
16.5.2006. Friday, 4pm. Went to local exhaust master to tune up exhaust pipes. He did the great job. Lower strut bar is on again... :D And the sound is great! :D Hondaiiiiiiiiiiii
16.5.2006. Friday, 6pm. Both spark cables, and distributor. Changed it. Engine works great again. No more stalling!
17.5.2006. Saturday, 11am. Wiring my new piggyback for A/C, fans, shift light, VSS, TPS, RPM, etc... Done around 8pm. Tested...
17.5.2006. Saturday, 10pm. Tuned up algorithm (software) for piggyback.
18.5.2006. Sunday, 11am. More tunning on piggyback. Now A/C works. Still have some tunings to do, but it works. No more damn heat on this sunny, hot days... Shift light lower it self to 3k rpm when engine is cold! ;) Great! :D
18.5.2006. Sunday, 4pm. Engine want start. Damn accu and alternator. It seems that alternator isn't strong enough, even I have put stronger wires. 70A is to low. I need 100A one. Damn. Engine stopped working on LPG!!! Damn! :(
19.5.2006. Monday, 10am. Went to LPG master. We have fucked up for a few hours, and found out that ECU for LPG, or step motor for LPG isn't working correctly. Reroute LPG directly without step motor, so I can drive on LPG, while I figure it out... Engine have less torque on LPG then on gasoline.
19.5.2006. Monday, 1pm. Went to junk yard to buy stronger alternator (100A). On a fucking pile, I couldn't find right one! Damn.
To be continued... Project in progress... :roll: :oops:
Exhaust system...
Wizards of NOS
Denso Iridium Power sparks
Engine monitoring and NOS progressive controller by me
Second gear on NOS
Also some NOS shooting
In the upper right corner there is RPM, next to it on the left is average AFR. In the upper left corner, (000c) there is NOS bottle content spent in seconds (11lbs bottle on 50HP is about 300sec). Next to it in the upper line there is TPS position (L/F), A/C indication, LPG indication, Engine Fan status, 1st gear indication (different NOS map in first gear), etc.
When you put in the 1st gear, and release the clutch, instead of NOS bottle content, Engine monitor will put and start stop watch in the upper left corner. It will count to 20 sec or to the next start.
In the second line, on the lower left corner, there is NOS progression mark in HP. Progression would start with 18HP and in a few seconds would reach 50HP. Also, empty rectangle next to it would be filled and simulate BAR of NOS injected, as progression is reaching 100% of NOS.
On 70HP NOS shot, I could go as low as 5.8s 0-60mph time, on yokohama A048 street race tires. I didn't get it on video, because it's hard to hold camera with one hand, and drive and push nitrous with other.. :-)
My best time on 1/4 mile was 13.97s... It's ok for FWD and 2500lbs (1150kg) heavy car....
Here are some videos without NOS...
0-100 kmp/h in about 7s
Daewoo Lanos 2.0 16V 0-100 7.8s on LPG
Daewoo Lanos 2.0 16V 0-100 7.1s w/o NOS
5th gear 130-210km/h
Almost top speed
On dyno
Drag 1/4mile: Lanos GSI16V vs Honda Civic VTI 160KS
15.8.2007. Now I'm in some headwork business...
I still have to buy some new valves, get head done by machine workshop, and change the head...
Head is back from machine working. I did some valve polishing...
Head is changed and I can say that it's mad how car performs now. I don't have figures of power gain or time gain, I could just estimate... I would say that 0-60 time have lowered by 0.2s.. Now I could go as low as 6.2s on yokohama A048 without NOS...
I was on MAHA dyno-brake, and I get pretty big figures. 172HP without ECU remap...
For history purpose, current car overview:
Daewoo LaNOS SPORT 2002, GSI 16V
2.0 16V DOHC 173HP (127KW), C20XE
Power Cap for c20xe inlet
BMC CDA Air filter
Denso Iridium power Sparks
4-2-1 exhaust pipeline (c20xe stock)
Custom ECU remap
Custom exhaust system without kat
Wizards of NOS 70HP shot
Custom progresive NOS controller (by me)
Custom complete headwork, polishing, porting, lowering (by me)
Custom short shifter (by me)
Custom head lights, xenon, projectors, lens (by me)
OZ Superleggera (Pirelli Pzero Nero) 195/45R16
Eibach pro springs
KYB excel-g shocks
Custom Aluminium grill (by me)
Electrical Hydraulic Servo Pump (Astra-G)
Dyno chart!
Now we are in some custom intake manifold business... :)
20.01.2008. Next thing I am doing is custom exhaust manifold, custom inlet manifold, but first, LaNOS is going VEMS (Stand alone after market Engine Management System) !
25.01.2008. After thinking for some time, the course of this project has changed. It's pretty hard to gain some big HP figures from N/A engine, so I'm going to change the engine with C20LET one (2.0 16V turbo, 204HP stock). Also I couldn't find a Lanos with C20LET engine, so I think I would give it a try!
With VEMS and some bigger IC, I'm going to 300HP figures...
Lanos SporT (C20LET inside) will be born! So let's shop first, and new pictures soon... :)
Engine Opel C20LET (2.0 16V 205HP from calibra turbo 4x4), Front upper and lower strut bar.
10.02.2008. I have done shopping. C20LET with coscast head is in tha house... :)
14.02.2008. Waiting for F28 (6 speed) gearbox to come back from the workshop...
26.02.2008. C20LET is finally inside with F28, 6 speed gearbox... Lanos Sport Turbo, Lanos SporT...
Lanos ST is born... :)
27.02.2008. Boooost is amasing... It's pulling strong all 6 gears... I assume that tops speed is around 160mph... I don't know for sure, because my speedometer isn't working correctly on this gearbox.... Still have some issue with engine overheating..
Inter cooler is mounted, now I have to make IC hoses...
15.03.2008. Front brake upgrade, front discs 284mm (from fiat coupe), calipers (from calibra turbo 4x4)
15.03.2008. Rear brake upgrade with 270mm discs and calipers (from calibra turbo 4x4)
20.05.2008. I was on MAHA dyno brake to have the initial values before the tuning business. :D It was a little below 200BHP (160WHP) and about 256Nm on 0.4bar. It didn't want to go to the 0.6bar witch is the stock value... I have found out later that the first gear switch was wrong...
So this is the moment for our memories... :D
My goal is 1bar with 1.3bar overboost and SA VEMS with about 300BHP and 450Nm... So let the games begin... :D
I have bought new distribution, water pump, and inlet cam...
Fuel Pressure Regulator...
Automotive Racing Products screws... :D
Had some work to do... Changed distribution, inlet cam, water pump, ARP screws, etc...
Ordered a new InterCooler from US... :D Here is compare of my new vs stock C20LET IC... :lol:
Catch of the week! :D It's a big fish! :D
Then I get impulsgeber (VSS) from DE, it's a "AD", 10 impulses per rotation.. Now it shows speed almost correctly, but I think it still shows a little less then the actual speed.. I will compare it to the GPS to be sure...
And then after a whole day of hard labor, the big fish IC is on the car... It's 29x6x5'' or 75x15x13cm, with 3'' (76mm) pipes... :D
Now I have to e-manage the engine and release the beast! :D Maybe I would get some 440cc injectors... :D And fix the hood, and the bumper (last winters crash :lol: )
01.07.2008. Working on VEMS...
05.07.2008. My friend Damir Muha, did the first configuration and the engine started... Alto the knock and hall sensor aren't configured, and he did only preliminary mapping with retarded spark, and the injectors are too small, on 0.7bar the car is like the beast on steroids... :)
In the second gear on good road when rpm reaches 4500rpm, it looses traction. In the third gear it's hard to control as it swings on the road as wheels are getting traction...
It pulls harder above 6000rpm, and pulls hard all 6 gears... Stock ECU and this one, alto the boost is only uprated from 0.6bar to 0.7bar, and with no overboost (stock had 0.8bar overboost) difference is big..
Now I need bigger injectors, and must learn a lot about configuring VEMS to enable LPG (bifuel staged support and knock sensor)...
12.07.2008. I put some big 630cc injectors...
13.07.2008. I have blown the engine. Probably fried the 3rd piston or piston rings... Will see when reap the engine apart...
The Lanos ST will be back soon with over 300BHP! :)
23.07.2008. We had the busy weekend. Engine was removed from the car, opened, repaired, closed, and reinstalled in the car on the public parking space... :) The third piston was fried, and second and third piston, piston rings was fried, too...
Second and third pistons were replaced, and everything was polished nicely... Thanks to my friend, Mutni...
We have spent many days working on VEMS configuration and wiring for LPG...
After many tries, and an invation of an active flyback for LPG lowZ injectors, it was working fine... :) On right picture it is a prototipe of active flyback... Thanks to my friend, Fire...
19.08.2008. My brother and I had a very busy weekend and the start on this week. We have installed A/C, repaired headlight housing (that was cracked on last crash), repainted grill, and the most important of all, we have mapped the car on 0.9bar (190kpa) on the local highway!!!! The car is pulling like a beast! I think it is now close to 300BHP!!!!
At the end of the day, to much power I wasn't ready for, and I have crushed the Lanos ST! Now I'm looking for another Lanos 3 door as a chasy donor.... The engine and the gearbox are fine, but the whole front of the car is gone... Damn! :(
09.02.2009. Finnaly, after long time collecting all the spare parts and after market parts, the car is at the workshop on chasy rebuild. It will be back cleaner and better looking.. :)
I'm working on a traction control (TC) right now. PCBs are done nicely. Now I have to make software for it...
