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Old 20-05-2014, 10:05 PM
Dust Dust is offline
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Join Date: Mar 2007
Location: Frankfort, Kentucky
Posts: 227
Default 2005 Ion Redline build/install

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...reeze/19232346
6 of these
http://www.walmart.com/ip/Super-Tech...l-Kit/33694255
A Cobalt SS (Redline's cousin) washer tank
http://www.ebay.com/itm/321395161584...84.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 filter
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

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.
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