2005 Ion Redline build/install

[Dust]

As of now, I am not quite to the installation. I am starting this as a motivation to get things going.

The Car
2005 Saturn Ion Redline Competition Package (Ladder tach/boost gauge, fogs, LSD, gunmetal 17's)
Mods
Bwoody Solid Mounts - to be replaced with Powell Race Parts mounts and an LNF(newer version of engine) mount
Header back exhaust minus kitty. 24" resonator and rear box/muffler. Loud
Engine mods
42 lb injectors
2.9 pulley (3.0 just in case)
K&N Typhoon Intake
Hurst short shifter

Plan for the car
My thoughts were to tune the car for 87 oct., and allow the water methanol to make up the extra octane. I've also considered 80Lb injectors with E85 and injecting mainly water, like 13%meth. Car is a daily driver, and I only really get to full boost about 1 time a week.


Part gathering
Over the winter I picked up alot of these
http://www.walmart.com/ip/Super-Tech-Gas-Line-Antifreeze/19232346
6 of these
http://www.walmart.com/ip/Super-Tech-Winter-Survival-Kit/33694255
A Cobalt SS (Redline's cousin) washer tank
http://www.ebay.com/itm/321395161584?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

It will install on the passenger's side, leaving the stock tank unmolested. it came with the pump and about a foot of pigtail/wiring. The pump outlet tubing is 5mm, but will accept 6mm tubing.

From documentation, the inline filter that aquamist has doesn't do well with pressure (feel free to correct me), so i will use my AEM inline filterhttp://ep.yimg.com/ca/I/yhst-15342291949654_2268_545030501
with 6mm to 1/4 NPT fittings from Ebay seller MettleAir. If I can get the pump in the bumper area it will go there, otherwise the filter will fit into the headlight area with the pump mounted to the passengers side of the engine bay.

I will use a modified OTTP LSJ Throttle Body spacer
http://www.ottperformance.com/store/pc/catalog/tbspacer_detail.jpg
Modified because there is too much thread for good atomization for the nozzles in the current location.

I might also install a SC to intake manifold spacer for post SC spray, as it is only $50, and would help with belt sizing issues.

The hard part
I went Aquamist because I wanted to tune for the kit. The issue I have is that I only have two choices for use of the failsafe.

1. Allow the computer to normally control boost when the Aquamist kit is on. When it is turned off or encounters an issue, it will send full power to the bypass valve which will cut all boost and the car will run NA.

2. When the kit is turned on, the boost bypass is turned off, meaning the plate is fully open, and the ECU cannot control boost at all. When the kit is off or encounters an issue, it will allow the ECU to control boost again.

Honestly, neither is what one would hope for.

[Richard L]

I hope you can continue the posting. We do offer an inline high pressure filter that has much less resistance than the AEM's.

Try blowing through it and let me know what you think.

[Dust]

Due in most part I think to surface area I think the AEM flows better than the Aquamist piece I have. I think the primer pump would be enough to negate it either way. I would be remiss however to not cry "links" when you mention a product I haven't seen before.

I started with a Purolator F20011
http://i.ebayimg.com/00/s/NTU3WDEwMDA=/z/jOYAAOxyeZNTTd4P/$_57.JPG
The 1/4" tubing would fit very snug inside. When the shurflo got too old to pump from the rear of the car I stepped up to 3/8" OD hose with fittings on tank, AEM filter, and pump.

[Richard L]

Surface area is one factor but micron size has more effect on restriction. What is the micron size of the AEM filter?

Blow thought it... the AEM and aquamist


You are showing what look like a paper element filter?

[Dust]

According to http://www.summitracing.com/parts/avm-30-3003?seid=srese1&gclid=CjgKEAjwnfGbBRDlxoHrl6uikyESJAD-nzCFBtoyOFPcopdPZP5J58pB7P9zfl0a-7BD7qazBWNYWfD_BwE

It's 40 micron nominal

And yes, that is a paper element. No issues that I could find with it coming apart.

[Richard L]

Do update.

On the aquamist systems, we use 100-120 micron elements as any particle smaller will go straight through the system. This also helps with flow and clogging up the element.

[Dust]

The nozzles I was using at the time had 80 micron nominal rating, and the filter was both easier to get to and had more surface area than the nozzles.

Where's the link to the inline filter?

[Richard L]

Sorry, here is the link:
http://www.aquamist-direct.com/806-259-hi-pressure-inline-130um-filter/

[Dust]

Found a decent deal on a Howerton 2 gallon tank with pump/wiring, hose and DO nozzle/holder. Extra parts and a good tank setup. Considering trunk mount.

I also ran a tap through the aem fiter so the fittings I bought would mount snug. That and the gun stock mods I did over the weekend have me coughing up black plastic. :) Need to vacuum badly. Hoping to get a keyless entry installed in the next few weeks, and have the company doing that tap and run the necessary wires for the kit connections. There is an empty cubby under the steering wheel, and another empty area under the HVAC, but without access that I can find, that I am looking at for mounting the brain. Will also be ordering a 2 or 3 gauge pod. Looking at an A-pillar, or this http://www.ebay.com/itm/2003-2007-Saturn-Ion-Custom-Gauge-Pod-52mm-Cluster-Bezel-Trim-OEM-/261490310690?pt=Motors_Car_Truck_Parts_A ccessories&hash=item3ce2097e22

[Dust]

I am very much considering picking up the Howerton Engineering tank, pump etc for an HFS-4 in the trunk, until I figure out the washer tank situation.
The engine and transmission mounts are finally on their way after 6 months and 3 days of back and forth.

[Dust]

Picked up the howerton tank with wiring and aquamist pump. Richard will soon receive paypal for my HFS4-v3, got the SC spacer, and the TB spacer will soon be worked on.

Richard, If I am putting a nozzle before and a nozzle after the SC, what ratio should I be looking at? Running 42lb injectors, and will probably run about 30% methanol.

[Dust]

HFS-4 came in faster from GB than a package from Amazon two states over. I tried to install the washer tank and evidently I got the tank from the Cobalt SSNA, instead of the SS/SC. So $50 down the drain. Found an SS/SC driver that had one for $20+shipping, and got some pictures of how it mounts, so i will get it installed when it comes in.

To Richard or anyone reading, with the shape of the washer tank (see below), would the place the washer pump is at be a good place for pickup? There is a half circle shape at the bottom of the tank where the pump mounts, and there is already room for 6mm hose to run. I would mount the low level sensor halfway up, about where the connector for the pump is, and run the wiring up that indention.

I will use the intank filter if it isn't too long, or the AEM inline filter if there is worry about debris.

https://fbcdn-sphotos-f-a.akamaihd.net/hphotos-ak-xap1/v/t1.0-9/10593183_745327732192104_297778107709505 1281_n.jpg?oh=c3d08ea8608ffe0d6c01b264e2 0718a4&oe=546F8EB1&__gda__=1416969837_aa0f6460002fdca9a08c4 1713e883417

[Dust]

$20 tank a no go, but have a few more lines on other ones. None of the normal places have them (Rock Auto/Ebay) as somehow they believe that the SS/NA and SS/SC have the same tanks. Next weekend I hope to have tint and keyless done, and will have the shop run an injector wire and map wire to the cabin. My only concern now is mounting the FAV. The nozzles will be on the driver's side of the car, but the driver's side has ABS, HID ballasts, ECU, and fuse block as seen in the picture.
http://i155.photobucket.com/albums/s288/ocshaman/IMG_20141026_163611_zps0c5ed1b7.jpg

My only choice is to mount above the radiator, above the engine, near the ECU/fuse block, or in the bumper area. I am leaning towards the bumper area as it would be closest to the nozzle, and furthest away from the electronics and heat, but most likely to get wet. I can post a pic of the bumper area if anyone would like to see.

[Richard L]

I am confused, you got Howerton trunk tank and now you are installing another tank in the engine bay?

The HFS4 pump or relay cluster will not last very long. You probably already know.

[Dust]

Richard, I found an HFS6v1 for cheap a few months ago, and considering using it as the HFS-4 is setup for DI.

I am also trying to keep the trunk empty as the only place for the Howerton would be in the back corner, and having it there would make carrying rifles a hassle. I am still considering putting a cheap PPS system with the pump mounted to the engine mount via a bracket. But I just found another HFS-6 for ridicucheap plus shipping, so I don't know yet. :)