Astra G C20XE/C20LET conversion guide

[bucky]

Well i'v recieved a few PM's latly about mk4 redtop conversions so iv compiled most of what i know into a hopefully useful guide

Wiring:

Same as mk2/3 to clocks, (rev counter, eml, oil light) , but dont wire up the water temp gauge(they work on milliamps from their own ecu on mk4s) so just stick a temp gauge in somewhere else.
Wire up your own external fuel pump straight to the fuel pump relay. Disconnect the radiator fan from the ecu it normally runs through and use an in pipe adjustable fan switch(from demon tweaks) and keep the mk4 radiator, then obviously the Xe ecu live and earth.
Keep the Mk4's original alternator starter and the wiring with it.

Gearbox:

Use an F23 from a 2.0 dti or 2.0 16v mk4 (2.2 astra and all vectra B boxes do not fit) also use the shafts for that box, the clutch pipe will connect straight up

Engine Mount:

This is the bit where i think you might get stuck, every c20'd mk4 iv worked on/helped build has had the timing changed to LATE type, a hole cut in the front and back cam covers a hole tapped in the block and a half the standard mk4 mount fitted and half a diffrent mount but i dont know what the mount was from. Heres a picture of the part number that might help, cant really make out the numbers that well though.



Or i have heard about people welding a bracket to the underside of the chassis leg but dont have any more info on that one.

Other issues you might come across: Top hat, lose the sfi box and use one for a corsa conversion. Rear water hose(the plastic one) needs changing for a diffrent one, but ill find out what one it is.
heres a bit of inspiration lol

apart from that it should be pretty easy to figure out.
If any body wants to add to or correct me then either post or PM me
hopefully this will help people any other questions keep to this thread please

Bucky.

[vaux24v]

good thread bucky, come in useful has that, i will be seeing mr feather when it comes to it to finalise what needs doing and to make sure i get everything i need.

[Paul]

Good thread, just replying so I can find it again!

[chip]

Good thread, a few more details filled in would be ace.

[bucky]

which details would you like?

[chip]

Wiring colours, that elusive mount number, some more detailed pictures.

Its great as it is, good to finally see some good mk4 gen on here, just if anyone else doing it can fill in a few blanks, it would be even better in the future

[DaveB]

Marks' elusive regardless of what you might need to talk to him about, lol

[saabturbonova]

i have a feeling the mount tht goes to the block is the astra 4 x20xev part. not 100% tho but its a start.

[chip]

FPMSL @ your sig:

If carlsberg built a saab turbo nova, png still wouldn't like it!

lmao

[saabturbonova]

aye ya gotta love it! bunch of to$$ers over there. dont get me going................

btw chip whos going to pv from vauxsport?

[stuartp]

very useful bucky i do remem pming you some time ago for some info. thanks

[bucky]

copied from threads found through search function:
Thick red wire with a ring connector on the end goes to the the battery.
Black wire goes to ignition live.
Thick red/blue goes from fuel pump relay to fuel pump.
The engine will run with those three connected.
After that:
Green=rev counter.
Brown/blue=EML
these might help with dash wiring as the colours are the same.:



heres a very useful site for checking enigne faults etc whe managment light comes on.
http://www.topbuzz.co.uk/info/fault_...ault_codes.htm

[vallanc3]

ill be using this as a guide in the new year! cheers buck

[wayne85]

looks handy that

[vaux24v]

think im gunna speak to mark when it comes to me putting mine in, will remind him about the dirt cheap 3.0 block he got off me lol

[chip]

btw chip whos going to pv from vauxsport?

Almost everyone mate, see you there

[vaux24v]

one thing i heard bucky is that the mount setup you show had to be late timing setup????? i have early and got told had to change to late but i aint doing ive already got to many bits to change lol.
no way im selling my verniers,water pump,timing belt kit etc to get all new again.

[elitedriver]

any more info on this mount? is it an x20xev mount? anyone with the electronics parts catalogue? could you cross reference the number?

[vaux24v]

my xe is going in next weekend bucky. the xev has given up lol.
i aint using the mount like you show above as mine is early timing set up and there no room between tensioners for the bracket so im gunna be fabricating a mount from the orignal xe mount position on front of block and probably going intp chassis leg. gunna make a mock up mount while xev is in and bolt it to that so i get it in right place and then i can just drop the xe in.

[elgan]

info on clutch and flywheel when using an f23 box?

is the f23 2.2. box suitable? sure i read somewhere about the starter motor being mounted upfront on the 2.2?

what engine mount bracket and rubber do people use when they weld a nova style o/s mount onto the chassis leg?

[wkd astra van]

can the c20let clutch and pressure plate be used with the f23 box?

[bucky]

info on clutch and flywheel when using an f23 box?

is the f23 2.2. box suitable? sure i read somewhere about the starter motor being mounted upfront on the 2.2?

what engine mount bracket and rubber do people use when they weld a nova style o/s mount onto the chassis leg?

correct, a 2.2 has the starter motor at the front. will only work if you swap the casing for a diesel or zlet f23.

use the flat type flywheel and a calibra turbo clutch.

[elgan]

do normal 1.7 dti shafts fit the f23 box out of interest?


seen a pic of a 4 stud ex dti van running an f23!

[Mark opy]

Good info

[elgan]

any more info on the gm part numbers for the drivers side mount? or what cars the mounts off so i can get numbers?