Isuzu Engine Astra MK3

[TDNova]

mullen i would love to help you out i an in bradford, next to leeds if you want a hand let me know

[MattyD]

so do you turn the nut on top of the diaphram? they didnt mention that on the corsa sport guide?

[MattyD]

ooops my bad, didnt read it properly lol

[dangerousbryan]

can you show a piccy of where to put T the boost gauge into please?
bryan

[Allvaux]

I used to have a Corsa 1.5td that one of my mates had increased the boost on (I think thats what he did anyway) by undoing a lock nut on the waste gate and turning the nut underneath by a couple of turns (or maybe less!) it defo went quicker, not sure what effect it had on its long term reliablility though cos I only had it just over a year!

That sounds remarkably like the trick that was common on D.I Transit diesels. There was a blue plastic cover on the fuel pump and we used to cut into this with a small hacksaw blade then undo it with a screwdriver. Behind this cover were two nuts, if memory serves correct the rear one was a 19mm and the front one a 13mm. The trick was to undo the 13mm one and slacken (or tighten) the 19mm one quarter of a turn then do the 13mm one back up tight again.
This combined with adjusting the throttle stop meant a bit more power-usually enough for a few months before the engine blew up!

[russpazz]

what would turbo, injectors and induction of a izuzu 1.7 td make to the 1.5?

o cheers for the guide

[Subarupaul]

Not a jot ISTR they're the same

[shamone79]

Check my post here!!

http://www.cavweb-forums.co.uk/showt...=77961&page=13

Uh-oh, should I have done this?? Know its another forum but some really relevant stuff here.

Shamone79

[adgie]

so is it poissible to get the white ring out without taking the manifold off?

[wayne141280]

where abouts in north east are you mate

[shamone79]

so is it poissible to get the white ring out without taking the manifold off?

If you cut it off yes, but if you want to keep it you need to take off the manifold.

You need to be careful not to change the alignment of the plunger i.e turn it, and this is easier to mark etc with the manifold off.

The manifolds are a piece of p**s to take off anyhow

[Corsa Tdi]

i dont knwo what the most anyone has had out of the 1.7s but i saw one with a quoted output of 130 bhp, cant remeber the torque figure. and that was in a nova with no intercooler.

hello sir , this is from malta.. the island of diesel freeks lol, here in malta do much more than that, we fit big turbo's on them such as kkk turbos, garrett t25's , t28's , t3's and even a t4 !
for example mine is with a ball bearing t4 turbonetics turbo.. the gtk series..
.. ok such mods have be done.. but not big ones!
the three thing that you mainly should have are, a good diesel pump , a well sized intercooler and a good turbo.. to do some real boost 35 psi ++ even 40psi with full boost
here in malta.. the avrage of a semi tuned engine is 14.7 sec @ 1/4 mile.. with a miserable nissan t28 turbo blehh ****ing not good, i would recommend a garrett t3 turbo (like the one of a cosworth ) and youll do 14.5's easy with no nitrous or any internal engine mods.. any questions just ask .. ahh btw i was just to forget.. ahh just was to forget.. last 1/4 mile that i gone.. last week.. my friend went far across the line than a tuned sierra coswort 2wd .. the cosworth is near the 400 hp and nothing to do with that mad isuzu hehe these thing that i mentioned seems to be all lies, but no !! just the true real story cu guys

[Corsa Tdi]

Taking the inlet manifold off is the best way to get to it,
the guide on cs says to cut the polo ring, but there is no need for that. (i.e. reversible mod)
taking it off however isn't as easy as it seems, it's held on by two 12mm nuts and five 8mm bolts,
the bolts are the problem:

as you can see they are not regular bolts, i bought a socket for them, was
a stahlwille item part no. 50 size 8 (12 edges...dunno the proper name)

Here you can see that there isn't much working space between manifold and pump.
(this used to be the big flat manifold which also houses the filter)
the safety valve can also be seen sticking out of the manifold, not all isuzu's have this btw.


From this point, make sure you're working as clean as possible,
you don't want any dirt getting in the pump, onto the plunger etc.

Once the manifold is off you can easily see the four 10mm bolts, undo the four bolts,
slightly bend the fuel return pipe and gently take off the cover

Then you'll see the rubber diaphram: DO NOT rip it out, firstly mark the nut on top of the diaphram
(turning it = adjusting it, so you'll need to know it's original position),
then take it out (you may need to turn it a little to get it out)


The pump without plunger & diaphram:

The plunger with diaphram:

the white polo, i knew it was in there somewhere !
(note: the cone at the end of the plunger is eccentric, therefore if u turn it, you're adjusting it...
look at it closely and you can see the markings on the cone made by the follower in the pump )

now, take it off:

Hammering the dimple out of the cover will make the plunger come up higher
and only affects the smoking when it's idling / not boosting (not really necessary i'd say)

Now, put the plunger back in it's original position (again: you may need to turn it to put it in),
make sure the edges of the rubber diaphram are in the groove,
then put the cover back on, push the fuel pipe back and tighten the four bolts.

The mysterious antitamper cover....can easily be removed with a big flat screwdriver:
just put it between the pump and the base of the cover and turn it and it should come off
If not, use all means necessary to get it off ! lmao

Underneath it is a 13mm lock nut and the max fuel screw, mark it's original position,
then undo the nut and turn the screw, how much is up to you: 1/2 a turn is a lot and
you might want to adjust it to your own need.

If u start the car it will idle a lot higher (remember turning the max fuel screw)
therefore you need to adjust both the cold and hot idle screws: (blue for cold, red for hot):
these also have a lock nut on them (8 or 10 mm spanner will help you out)


Turning up the boost, using a bleedvalve or MBC.
Extra parts needed: 4mm boost hose (or fuel hose, which is also very strong),
clips or hose clamps AND a boost gauge with parts to install it (t-piece and pipe)

Look at the turbo and source the pipe that goes to the actuator (sits on the back of the turbo),
use some pliers to undo the clips and take off the hose, depending on the car
and turbo you could either cut this hose in half and put the bleedvalve/mbc inbetween
or use some extra boosthose to fit it (that's what i did):

don't know which way to put it? it's from turbo->bleedvalve/mbc->actuator

How much boost ? Can't tell you; in original form the nova's/corsa's run 0.68 bar and the astra/cav runs 0.8 bar...
i.e. you're on your own here (and i take no responsibility if something goes BANG!) lmao

If u have a safety valve, then +/- 1.1 bar is as high as you can go, want to go up, mod it !
Put the valve in a vice (upsidedown), then drill into the center until the center comes off:
(center is on the right), then you can take the valve apart:
I welded a big nut (14 or 16mm...dunno exactly) in the valve and removed the ring on top:

Removing ring on top:


Cheers, J

there is much more to do there ! but you are @ the right point mate

[Jack]

Get some photos up of your crazy engine!

[fury373]

Hey you fellow carnuts, great to find info on tuning the astra 17dt / tc4ee1 isuzu engine.

I'm rebuilding and converting an opel astra F (mk3) from 1993. It will have the isuzu engine (chassis member did need work for that) slight body modifications, leather interiour, lot's of electrical stuff etc etc...welding and paint etc

But to get back to the engine.. i did take mine apart. new piston rings, new seals, new bearings, new (all metal) head gasket, ported the inlet manifold to the head (you won't imagine how much that deviated from the head...about 3mm top and bottom..can't flow properly it would seem). i've also had the pump rebuild and set to it's upper factory values. Inlet had been slightly polished. turbo and intercooler have been unchanged (have been thinking of larger intercooler, but with all the other mod's i've even had to place my horn into my wheel arches behind the plastic plate...so larger intercooler would probably become outside the bumper then) thinking of sealing the topcover to the manifold(where normally the air filter is located) and then mount a custom open airfilter to the inlet. thinking of one of those where the filter is in a box with a hose that i can route to the front for more cold air.

Hope to run the engine in in this configuration. maybe tune it up a bit more later(possible the plastic polo ring) ...but the engine will have to be ok for many miles. Hope to drive it for about 5 to 10 years after all the work.

Suggestions are always welcome... and i see that the pictures came from a fellow dutch guy?...you are putting it in your corsa combo?

greetz, Hans

[mr cheese]

Hi guys

I am sorry this is again repeating LOTS of already answered questions, but I am in a little state of confusion. I have tried the links on here and read all I can about the white polo etc, but am not sure of the exact process. I have recently bought my dad a 1.7Td Isuzu engined astra and to be honest there is more power being dragged along by a pet dog than in this thing. I doubt it would pull the skin of a rice pudding as the saying goes....

Basically I am questioning the Turbo or at least whether or not the thing is indeed working. Chances are it is and because I am comparing it to the C20Let Cally I am driving, it is going to appear somewhat underpowered. My question really is:

Does anyone have a link for the guide of how to increase power of these engines... I have tried the obvious ones but the pics are down and am not sure of what I am supposed to be looking / searching for. I had a good look and couldnt see the 4 10mm bolts described anywhere. Do I need to take the inlet manifold off to get to it?

There were LOTS of problems with the car, from a non working Temp gauge to a melted alternator-starter cable. I have repaired all that and found a split in the turbo to intercooler pipe. That too has now been repaired, but the car just doesnt seem to pull very hard at all.

If anyone has any idea of a site that still hosts the pics as well as instructions, I will be MOST grateful.

Cheers guys )

dont know if this will help but mine was exactly the same by the sound of it when i came up to roundabouts doing less than 10mph i would have to put it in first gear otherwise it would bog down plus i have had a vauxhall low blow diesel engine before and it was quicker than the isuzu was so didnt make sense like it didnt have a turbo long story short seized actuater once sorted flies (for a diesel) totally different car

[Prilo]

Hello mates

I've got a Cavalier 1.7TD-Isuzu engine. I want to make an intake like this on the pictures above. Mine is with a secondary air filter and with an overpressure valve on it too. Just like the one on the pictures above.

My question is, can I use an inlet from Astra 1.7TD, but the other type - without air filter in it? Check out the picture bellow:




I can bye this kind of inlet and, grind it here and there with the tools, and to "clean" it like the one above.

What do you think, mates? Is the other intake proper to do this mod, or I should modify mine original one?

Thank you in advance, for you answers.

[Prilo]

Anyone?!.... No one?

[DutchNovaDiesel]

The one i hacked up was the original manifold with the secondary airfilter on top.
(looks better, and as a bonus: i can swap injectors without removing the intake manifold)

The newer type manifold can not really be hacked / modified, you can however use it to
fit an intercooler, like so:

[Prilo]

Thank you for your answer, mate

The one you hacked looks great. Nice work.
I'll try to find a spare old type one. I'd like to keep my intake untouched..... just in case, if I want to put it back in it's original set up after while

Cheers.

[reno]

The one i hacked up was the original manifold with the secondary airfilter on top.
(looks better, and as a bonus: i can swap injectors without removing the intake manifold)

The newer type manifold can not really be hacked / modified, you can however use it to
fit an intercooler, like so:

would that inlet fit and work on the astra 1.7TD, made any mods to that inlet? and im guessing you had it chromed?

[sebbyg]

hello sir , this is from malta.. the island of diesel freeks lol, here in malta do much more than that, we fit big turbo's on them such as kkk turbos, garrett t25's , t28's , t3's and even a t4 !
for example mine is with a ball bearing t4 turbonetics turbo.. the gtk series..
.. ok such mods have be done.. but not big ones!
the three thing that you mainly should have are, a good diesel pump , a well sized intercooler and a good turbo.. to do some real boost 35 psi ++ even 40psi with full boost
here in malta.. the avrage of a semi tuned engine is 14.7 sec @ 1/4 mile.. with a miserable nissan t28 turbo blehh ****ing not good, i would recommend a garrett t3 turbo (like the one of a cosworth ) and youll do 14.5's easy with no nitrous or any internal engine mods.. any questions just ask .. ahh btw i was just to forget.. ahh just was to forget.. last 1/4 mile that i gone.. last week.. my friend went far across the line than a tuned sierra coswort 2wd .. the cosworth is near the 400 hp and nothing to do with that mad isuzu hehe these thing that i mentioned seems to be all lies, but no !! just the true real story cu guys

Hi, i have a corsa 1.5td, wanting to put the t28 turbo on it and also up rate the diesel pump as mentioned above, anyone know waht diesel pump will go straight on? thanks, Seb

[sebbyg]

would that inlet fit and work on the astra 1.7TD, made any mods to that inlet? and im guessing you had it chromed?

I'm also going to put a 1.5 n/a diesel inlet on to my car. where would i take the vacuum feed for the fuel pump from though??

[Prilo]

Some thing bothers me

If I take of the diaphram with the plunger, wouldn't the follower come out too much, because of its spring pressure? If it does, then how am I gonna put back the plunger? It will hit the follower and won't fit the hole, I'm afraid.

[Prilo]

Any advice?!.....
I really want to do this operation this weekend, so I'll be very thankfull for a guiding answer.