My astra C20XE conversion project

[DavebGsi]

Andy_Mk3 will be able to tell you, he runs an F28, but he knows more about this stuff. There is a SAAB 5 speed with longer ratios which is a strong box. I assume you can fit one to an xe as you can fit an f28 on a saab so it must be possible! FM55 I think it's called

 

[Varnis9]

Right... So we have done some more digging on the engine condition and I have some bad news...

Although the engine seemed good from a first look, unfortunately it is not.. Cylinder 1 is 5 tenths of a mm larger than the rest bores, while piston 1 is 3 tenths of a mm smaller than the rest. That explains the ruttling sound I was hearing before the last engine break down. Diagnosis shows that the problem was due to a faulty injector which caused cylinder 1 to overheat.







Anyway, as the engine is going to be fully forged I didnt really bother about the news. However I wanted to avoid reboring and the extra costs, which as things seem I will not..!!

Decision was easy to take, so I have now ordered a set of 86.5mm wossner low compression pistons, which will be paired with steel rods, new bosch injectors and lots of other goodies. I guess black friday came right on time for me Sadly, parts wont arrive before new year's as there's one month lead time!

 

[Varnis9]

Andy_Mk3 will be able to tell you, he runs an F28, but he knows more about this stuff. There is a SAAB 5 speed with longer ratios which is a strong box. I assume you can fit one to an xe as you can fit an f28 on a saab so it must be possible! FM55 I think it's called

Andy_Mk3 I would appreciate any help on the saab gearbox options mate

 

[Varnis9]

As the rain keeps going, and engine parts are still delivered, I have turned my focus on the interior. First thing I sorted out was the ecu loom. As said a few times already I am running on megasquirt so the custom wiring will have to be further customized in order to allow the loom to pass through the bulkhead, behind the engine, and connect to all necessary points.

Wired lambda sensor controller..



Wired rev counter adaptor...



Final loom with all connection points rearranged..





Then I tried to sort out something that always bothered me.. the ecu location. Took the original ecu bracket and modified to match the holes of the MS ecu..





Opening up a slot so that the rs wire can be connected for tuning...

 

[Varnis9]

Then took my time to cable manage all the wires near the ecu and secured the ecu in place.

BEFORE



AFTER

 

[Varnis9]

Rewired and fixed all issues with the ecu wiring loom.





Replaced the old cheap fuse and relay holder...





Next step is to test fit in the car!

 

[Varnis9]

More progress on the Astra this week.. Replaced the ecu connector with a 90degree to make the megasquirt fit properly in the original ecu location and bracket. I can now install the ecu back!





Also drilled a new 54mm hole in the bulkhead, and passed the ecu loom through. Found a spot next to the steering column. Should be nice and hidden.



Also did some wiring up.. Connected the ecu loom main battery wire to the bus bar (thorugh a small hole underneath the scuttle panel)..



Then routed the ecu loom and the new relay box to a somehow permanent location. I now need to create a custom bracket for the relay box, probably next to the ecu bracket... will see about that..


Next step is to carry on with the electric fuel pump conversion!

 

[Varnis9]

In the meantime, some new goodies have arrived!!

 

[Varnis9]

Although not so much been done on the car during the last few months, I have been ordering parts on the go. Today I received the latest!!

C20XE sump gasket and gasket set..



Brand new timing set, new racing injectors, and original conrod bearings!

 

[Varnis9]

Got some nice brand new blue injectors, I guess more ideal for 300-350hp.

 

[Kev_mk3]

Good to see it still being done

 

[DavebGsi]

some nice goodies there!