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My astra C20XE conversion project
- Thread starter Varnis9
- Start date
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- Tags
- astra diary c20xe restoration
Varnis9
Club Member
So a few of the major things that need to be arranged are the two black fuse/relay boxes inside the engine bay. The one is the main power fuse box which I will have to reroute under the scuttle panel. With the battery going in the boot I had to find a way to distribute the power from the battery at the back, then into the engine bay, starter, alternator.
So I replaced the old fuse box with a fused distribution block (had to buy extra fuses to maintain the original fuse amp rating). On the distribution block I will connect the battery, the ecu, alternator and starter.
Installed power distribution block near the whipper motor. I think this is the best location to put it. It gives access to the wires from the battery at the back, and also for all auxiliaries. I have screwed it down but will also add some silicon glue at the bottom later on, to hold it rock solid on the chassis. Dont want that come loose and flying around while driving!!!
So I replaced the old fuse box with a fused distribution block (had to buy extra fuses to maintain the original fuse amp rating). On the distribution block I will connect the battery, the ecu, alternator and starter.
Installed power distribution block near the whipper motor. I think this is the best location to put it. It gives access to the wires from the battery at the back, and also for all auxiliaries. I have screwed it down but will also add some silicon glue at the bottom later on, to hold it rock solid on the chassis. Dont want that come loose and flying around while driving!!!
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Varnis9
Club Member
Going on to the second relay box from the engine (from a quick research that's for the A/C and horn).. That's the standard box that is attached on the bulkhead inside the engine bay.
So.. I removed the relays and fuse, deleted the box, and rerouted the wires underneath the scuttle panel. I am thinking of getting a mini relay box to replace the 2 relays and wires, and tidy up the mess.
So.. I removed the relays and fuse, deleted the box, and rerouted the wires underneath the scuttle panel. I am thinking of getting a mini relay box to replace the 2 relays and wires, and tidy up the mess.
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Varnis9
Club Member
After sorting out the relay boxes.. the big challenge has began, that is to reroute and hide all the wires from the car wiring loom out and around of the engine bay.
All wires coming from the engine bay, including those for the aircon, will follow the path underneath the scuttle panel, then around the inner wing.
For all wires coming from inside the car I will keep the standard route and grommet, and just use a nearby hole to pass them through the side panel and around the engine bay. Once the water reservoir is in place, all these will be hidden!
Rerouted loom.
Extended and soldered all wires and wrapped in loom tape.
Horn plugs also sorted.
All wires coming from the engine bay, including those for the aircon, will follow the path underneath the scuttle panel, then around the inner wing.
For all wires coming from inside the car I will keep the standard route and grommet, and just use a nearby hole to pass them through the side panel and around the engine bay. Once the water reservoir is in place, all these will be hidden!
Rerouted loom.
Extended and soldered all wires and wrapped in loom tape.
Horn plugs also sorted.
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Varnis9
Club Member
I recently started shaving the engine bay. Removing all unnecessary brackets, battery tray, and marking up the holes that need to be filled in.
So main loom support bracket deleted.
Battery tray removed.
A few other bits here and there also deleted and smoothened. I will come back to all spots, later on for welding.
So main loom support bracket deleted.
Battery tray removed.
A few other bits here and there also deleted and smoothened. I will come back to all spots, later on for welding.
Varnis9
Club Member
Progress been a bit slow during the last few weeks. My other car has broken down so need to focus on fixing it, plus weather is not doing me any favour! Keep ordering parts, I hope to carry on with the new year!!
Varnis9
Club Member
Just wanted to give a quick update on the project, basically during the last months I have only been ordering parts, so no really work been made on the car.. Been unlucky also as my daily driver has broken down so trying to get that back up and running (another engine out project!!). A few of the things I have received..
Metal spark plug cover and cabin filter. Cover will go in for a proper paint job (in red.. obsviously).
Bulkhead connector for the ecu wiring loom for easy plugging unplugging.
A new brand new coilover/damper kit from bilstein. I ahve gone for the pro-kit as I want some ride comfort. Finally switching from the hard AF H&R kit!! That will be up for sale soon.
Brand new upgraded aluminium rad.
Test fitting the rad. Will need some mods to fit the second fan switch for the aircon, and also make some custom made mounting brackets as the original ones dont really fit.
Metal spark plug cover and cabin filter. Cover will go in for a proper paint job (in red.. obsviously).
Bulkhead connector for the ecu wiring loom for easy plugging unplugging.
A new brand new coilover/damper kit from bilstein. I ahve gone for the pro-kit as I want some ride comfort. Finally switching from the hard AF H&R kit!! That will be up for sale soon.
Brand new upgraded aluminium rad.
Test fitting the rad. Will need some mods to fit the second fan switch for the aircon, and also make some custom made mounting brackets as the original ones dont really fit.
Attachments
Varnis9
Club Member
a heads up for the project I decided to go the root of turboing my engine, basically convert to let. I know I might as well just buy a let, but i wanna do it at my own pace and also am up for the challenge. Been investigating all this time and started sourcing parts out. The plan is to go for 300-320 bhp. Despite the initial thoughts to just switch to itbs, I honestly think its not worth the price for what you get. Anyway, apart from the turbo I will fully forge the engine. Tried sourcing used let pistons, but unfortunately nothing I ve found could match my standards. Expected for 30+ year old parts!
I have recently received the first batch of parts to start the project.
A set of xe cams, will do the 7 deg adjustment.
A set of adjustable verniers.
A set of steel rods.
And a T4 exhaust manifold. Will probably modify to a T3, also block the wastegate.
I have recently received the first batch of parts to start the project.
A set of xe cams, will do the 7 deg adjustment.
A set of adjustable verniers.
A set of steel rods.
And a T4 exhaust manifold. Will probably modify to a T3, also block the wastegate.
F20 won't take the power for sure, f28 are very rare and expensive in england now, not sure about ur country?
Much better doing it yourself you will learn alot!
Much better doing it yourself you will learn alot!
Varnis9
Club Member
A bit of a progress today. Dash is out. Although I wanted to avoid this, I decided to remove it to get better access behind the dash to organise ecu and wiring.
I am thinkng of placing the megasquirt ecu behind the glovebox area. It seems there is some more space to fit a custom bracket.
I am thinkng of placing the megasquirt ecu behind the glovebox area. It seems there is some more space to fit a custom bracket.
Varnis9
Club Member
Really doubt f28s even exist in Cyprus!!
Varnis9
Club Member
Managed to finally get the XE engine out to start the rebuild process. Fully dismantled and checked. I am very glad that the cylinders are mint! for a 30 years old engine. Next step is to order the LET forged pistons and a ton of parts, gaksets etc, and get the block cleaned and painted.
Still in search for an F28…
Still in search for an F28…
Varnis9
Club Member
Didnt think of it tbh. What would actually be needed and what gearbox model?