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Ignition, Carburettion and Exhaust - in and out

Below are staple modifications which should be first on any 96 owners list of things-to-do. Most of which are simply bolt on yet will yeild the greatest increases in power and perofomance for some of the least time consuming jobs. Getting more and more power from the engine requires more and more money, time and effort for less and less gains.

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1) Replace the original, and very restrictive, exhaust with a Jetex sports version.

Retails in the region of �220-�250. I applied insulative exhaust wrap to the down pipes to reduce heat in the engine bay and and several tins of High Temperature exhaust paint to the pipes to protect against corrosion.

Jetex is the only aftermarket sports exhaust for the 96 and it is aluminiumised steel. Stainless replicas are available but share the restrictive problems as the original.

Bare in mind that although the larger bore of the sports exhaust will improve breathing, full benefit will not be achaived unles the exhaust ports in each cyclder head are ported to 44mm to match the exhaust.

2) Upgrade the original FoMoCo or Solex carb to any twin choke Weber. I plumped for the 32/36 DGV with a rather fetching sports filter. This imporves breathing no end.

The Weber DGV (or DGAV if you want automatic choke) is a wiser choice over the classic DCD range as parts are widely available.

Expect to pay �30-�50 for the filter and from �50 for a servicable second hand carb to up to �300 for a spanking new one. The real issue is sourcing the 2bbl manifold as the standard single choke manifold will not accept the 4 stud twin choke pattern.

I have chosen not to route the the breather pipe from the rocker covers into the air filter - as standard - but attach a breather filter to let the exhausts vent. This is to preven hot dirty air entering the carb and making the car too rich.

Weber DGV (and DGAV) jet settings:

                            Primary Barrel         Secondary Barrel
Main jet                         135                          140
Air Corrector                160                          190
Emulsion                         F5                          F16
Idle Jet                           50                            65
Pump Discharge Nozzle                50

Combined with the exhaust, one can expect a 15-20bhp increase automatically.

When replacing the inlet manifold gasket - save the small copper plates that are attached - find out why here

3) Electronic Ignition set. I chose the Pertonix (which also goes under the name "Aldon") because, well, they also make a shiny chrome coil called the "Firebreather" so clearly marketing does work. The part number is 1847A. Lumenition also make siimilar kits for the 96.

Gone are you contacts forever, a real 'fit and forget' peice of kit. The most complex proceedure is turning the engine to tdc but the whole process can be done in 30 minutes. Gives for much better/reliable ignition and the opportunity to run with slightly wider spark plug gaps because of the increased power.

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4) Magnecore 8mm HT leads - not an essential upgrade but going to the trouble of uprating the alternator, coil, ignition, and plugs warrents a few more pounds spent on the wires that carry that all important current. Magnecore offer three grades of cable: 7mm, 8mm and 8.5mm, all pre-cut to the 96 specs. I opted for the 8mm set as a compromise between cost and performance. Part numbers; 47457, 40457 and 45457 respectively.