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How I Turbocharged my G200 This is a HOW TO of sorts and will apply to pretty much a G200 or a G100 for the fitting of a CB61. The minor adjustments that will have to be done to the G200, and things to remember are following; 1) A CB61 fuel pump WILL be needed to be installed in the tank. 2) the alternator connection has to be connected to the older cb61 square clip. the alternators are physically different sizes, no biggy just 2 snips and 2 crimps. 3) You wont need 2 fuel filters so i recommend that the plastic clear one goes and the on attached to the cb61 fuel pressure regulator is kept, plus it helps with mounting the unit 4) don't get carried away and install the CB61 loom, there is nothing for the dash light to flash anyway and you can remove some of the pollution gear this way. 5) the Hoses for the radiator have to stay with the car, the radiators are different. And there are odd sensors for the G100 which include one in the pipe for the thermostat, this isn't on the G200. 6) G200 Box must stay with G200 but it mounts up to the CB61 perfect anyway Removal of original engine remove the bonnet before even any work starts You will need to start by one by one removing wires from the engine, distributor power, sensor wires ect, labeling them as you go. (best done with masking tape folded to make a tag) Once that is done you can undo the exhaust from the bottom of the catalytic converter so the engine can be lifted out without bringing the zaust with it... Next is the CV joints. This is a annoying part but not hard at all. Jack the front of the car up and place it on engine stands. Take the wheels off the car and then there will be two big bolts holding the struts (the things inside the suspension spring) to the wheel. Remove these two bolts and the front disc and hub should be able so swing around enough to pull the cv out of the transmission enough. Do this on both sides then place the exposed cv joint in plastic bags to avoid dirt and shit getting into the grease. Accelerator and choke cables are simple to remove, the accelerator cable is just hooked in to the carbi part by a little knob on the end of it, with your hand pull the throttle open and unhook the cable with the slack you just made, undo the screw clamp holding the cable outer part to the engine and ur done. Choke cable is much the same.. Clutch cable is relatively easy as well but can get tricky sometimes. Adjust the cable tension as much as possible to give yourself as much slack as possible. then unhook the cable from the clutch arm. done. don't forget to take the Speedo cable and the battery earth from the transmission or you have fun getting engine out. Loosen engine mounts and totally undo the torque stays (aka front and back engine mounts which are on the side of the block) The selector arm linkages on the gear box side are to be removed Radiator hose is next to go, drain the radiator first from the bottom of the radiator where there is a tap. Fuel lines are disconnected at the engine side so the hose just sits in the engine bay, probably a good idea to plug the holes with a screw or bolt around the size of the hose You should now be ready to lift the engine and box out of the car all in one piece. There is a hook on the exhaust manifold and a loop on the intake at opposite ends of the engine, get chain and lift from these points... slowly and make sure everything is actually unattached. Once the engine is lifted about 2inch take the side engine mount bolts and guide the engine up out of the chassis slowly then role chassis back and lower engine. Install of CB61 to a G200 You can drop the box and engine in if you want straight up but i recommend swapping for the G200 box because the G100 box wont fit. Clean out the engine bay as much as possible while its empty. this makes for clean easy work and is much more enjoyable if you don't get a eye/hair/hand full of grease at every touch while under it. Installing is much the same as the removing of the engine just in reverse. The different things will be;
Take the tank out of the G200 and install the new pump, this is piss easy, just cut the pick up copper line about 3 inches shorter and then attach the pump to a piece of fuel hose and then the other end to the feeder line and it should be 100% stable. drill 2 wire size holes in the plate which has the in/out lines in it and feed the wires thru from the fuel pump and earth one to the tank on the outside and one to the ignition +ive. seal up with some fuel resistant epoxy steel and your set. make sure there is a filter on the sucking end of the fuel pump or u might damage it. If possible use the dizzy from the G200's original engine, its electronic and works better with the coil which is a cunt to swap around car to car. Fit the CB61 to the G200's gear box, this is simple, check which clutch is better and use it as they are the same. lower engine into the chassis and do up all the mounts, the mounts from the G200 must be used also for this, no biggy tho just undo them from the old engine and put them onto the CB61. Connect everything that was disconnected in which ever order suits you. just make sure its all good and the engine has oil and fuel filter before its started. WATCH IT CAREFULLY for a few minutes.
Everything is quite vague in this but that's because its all quite simple and i cbf explaining it well. if there is any questions about this conversion then just send me a email or msn me, ill be happy to help. From a CB23 to a CB61 is very easy and can easily double the HP the car had :D enjoy |