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Old 21-02-2008, 09:15   #1
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GSi 8v build - x16xe out...i have the new powerplant!

Well i have just picked up this little beauty. An N-reg Corsa GSi with an X16XEL engine and in good condition. Got big plans for this...hopefully to be done in time for PVS '08 and the huge trip through Europe that will follow straight after Engine is a recent rebuild that has had the head replaced with the wrong head bolts, so when its cold it sounds like an ill lawnmower. Once warm it runs fine! :lol:







Plans are, to get a C20ne/seh in it, and run on R1 carbs. Am getting Janspeed to make me up a stainless custom manifold to mate the Corsa system to the Engine exhaust set-up.
Tidy up the exterior, theres a few knocks that need sorting, but nothing major. Then get slant panel and front cross-member ground back, etched and painted.
I am changing the suspension set-up from coilovers to Bilstein shocks and spax 50mm springs and have got some Pro-Race 1.2's to put on it in the end, will be getting Compomotives for the winter. :look:
Interior will need to be played with, but again i have some big ideas. I will be putting a black carpet, door cards and Sport seats or RST Recaro's (if i can find a set of the recaro's)

Some pics of the R1 carbs i have to go on it!




As the car came with various parts that i dont want/need, i started stripping it down.

First off, was the suspension. Spax RSX coilovers to be replaced with Bilstein B8 dampers and Spax SSX 50mm springs.
Was goin well until i took one of the front coilovers off. I went to put the new shock and spring on and of course there was no spring seat on the top mount. :| So i have had to just leave the front c'overs on and change the rears until the ordered parts come in from vauxhall
Oh...and i took the front ARB off it as well! :P

Spax off...


And Bilstein on ...


How she now sits...


Next i cracked on with taking the harnesses and one of the seats out (need drivers seat to move it to and from in front of the garage).





That was it really, all i could do for the day.

Wed 13th Feb

Well i had a couple of little jobs to do today. Still waiting on the spring seats from vauxhall so had to find other things.

I decided to take the opportunity to wirebrush and paint the drums with black hammerite.
Once the paint was dry, i thought i'd see how the bk end looked with the Pro Race's on.





Hoping that after a week or so of use, that back end will drop, but also realised that there isnt an interior or anything, so it will sit slightly lower once its on the road.
Was made up to see that you can see the Bilsteins through the wheel...so i'm able to show off the quality suspension system! :P



Apart from that i took the front bumper off, and gave the inside a quick brush!

Once darkness fell i concentated on repairing one of my alloys that an ARB bracket on the car im driving gauged a 'diamond cut' ridge into them when i had them on it for a week





It's on the inside rim so you cant see it but thought i'd sort it to protect it anyways, so i managed to repaint it gloss black and re-laquer it and is all protected and looking ok now.

Feb 14th and 15th
Well last two days off work so i HAD to get everything done. The jobs remaining for these 2 days were to take the front coilovers off and get the parts that i was expecting from vauxhall to complete the new suspension set-up.

Thursday - So...up the front end went on axle stands and i cracked on with getting the coilovers off...which didnt take long, although cracking the two bottom bolts free was a bugger, it all came off pretty easy!





So, once they'd gone, i decided to sort the brakes whilst i waited on the suspension parts. As is a common problem, the bolt for the brake discs was goosed...so i just drilled the head off it and off it all came!









And the pleasant discovery that the car has got braided brake hoses, which will save me some money!




The bad news arrived about half 1 when i rang vauxhall and they told me it was gonna be friday morning b4 the parts were in now. Annoying as the car was on axle on my mates drive with his dads car in the garage behind. Logistical problems were to be worked around but was still a pain.

How thursday ended:


Friday Well i went absolutely steaming into it today...out before 9 to get cracking. Day started well, with vauxhall ringing me at quarter past 9 telling me my parts were in. So down i trundled to get em. When i got there, i found that i had missed a part i needed on the order! So went round the corner to a scrappy and managed to buy 2 front set-ups off a sport for £30. Then back home to try and take em apart for the spring seat.



Once i started to try taking them apart, the nut on the top would not budge. Adam-D attempted it and still nothing, managed to break a socket and hurt hands without getting anywhere as it was really rusted on!



I was all but ready to quit on it for the day but decided to take them to a welding and bodywork shop around corner where the owner kindly cracked the nut loose wit his air gun! back in buisness!

Got them bk, compressed the sping and shouted victory abuse at it! :lol:
Sat the standards alongside the Bilsteins, ever amazed by the huge size of the B8's piston!





So...undersealed the turrets, and prepped them for the new shocks and springs.


Built up the new shock and spring unit, with the help of my ever present and highly useful girlfriend! :look: Having a second pair of hands is always useful, and she was able put the top nut on whilst i pushed down on the top mount assembly to compress the spring just enough.
Was extremely pleased to see it all finally together.


At this point my phone ran out of power so i couldnt get anymore photos...however i will get pics and put em in here asap.

Once the suspension was on i changed over the callipers, putting a 2litre set-up on with red-dot pads and 6 Groove Discs.

With the wheel off now, it looks the dogs danglies. Red-dot, Bilstien and spax.
I ended the day, and the week happy that i'd done everything i wanted to do!
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Old 21-02-2008, 09:58   #2
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looking good mate, how come you changed the coilovers for fixed suspension kit?, what is the rsx setup like? for sale? keep us updated will be following this one
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Old 24-02-2008, 09:08   #3
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I dont like the coilover theory. Adjustable is bad! Unless you get it set up properly, the suspension harmonics wont be right! However a fixed system that works at a fixed rate means better handling. I know from experience of 2 other people's cars.

The bilstein system is spot on...and in comparison to the coilover'd car, cornered better at speed because the dampers were able to take bumps whilst under compression and reset without affecting the car's balance, whereas with coilovers, any bumps in the corner arent absorbed by the suspension and can throw the car off..which can be very bad! lol.

Sorry bout the essay, but its a well thought-over answer! :P
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Old 24-02-2008, 09:09   #4
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Sat 23rd Feb

Well i managed to get a bit more work done today...tho no pics.

With the engine coming out this time next week, i spent the day trying to get the ancillaries off. Exhaust is all loosened just needs pulling off now.

The main bugger was the starter motor. It just will not come off!! Dont know if anybody knows whether theres more than the one bolt and one nut i took off...but its still solid.
Took a look at my mate adam-d's C16 which he has out in his garage and it is only the 2 bolts on the starter, so im assuming the X16 is the same?? Pain in the arse. Just the alternator to do once thats off, oh...and drain fluids out.
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Old 24-02-2008, 09:13   #5
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one of the gearbox bolts will be holding the stater iirc
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Old 24-02-2008, 12:40   #6
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yea i thought that...but i took the gearobox bolt out and its not holding it. The nut i've taken off apparently is on a bolt that then needs taking off. So i've just missed it and then it shoud come off!
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Old 24-02-2008, 13:08   #7
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looks a good project, love the colour, reminds me of my mates old xe
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Old 02-03-2008, 20:15   #8
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Sat 1st March

Well, another weekend came along and the next big step has been taken. Although i had my fears the weather would prevent it, the engine removal went ahead as planned.

Pretty much everything was ready for it to be taken out, so once the driveshafts and engine mounts were released...out it all came. Only took us about an hour to do the lot, and i was mightily impressed.

As there was just the 2 of us doing it, i didnt have the opportunity to take progressive photos, so they all from once the block was out.









So its all out and ready for the eventually rebuilt c20ne to be popped in.

This x16xe is now for sale...so gimme a shout if you're interested...i really need both the money and the room!

Sun 2nd March

Although there was no work done on the car, i picked up the engine today. Appears to be in good condition. Adam has the photos of it as my phone ran out of power again...seems to be a thing when i need to take pics!

Just need to get it stripped and find out what its all like inside. Then get required replacement bits and bearings, new gaskets on...back together and running on the carbs ready to get into the car!


Thanks for reading again! Keep you posted on further progress this week!
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Old 12-03-2008, 08:33   #9
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top end off the 2 ltr

Tues 11th March

Well its been a while since i've done anything sincere before today. Last few days iv been trying to find a way to get the recaro's to sit on the corsa frame but am gonna have to have them welded.

Strengthening plates arrived the other day so im gonna have the car collected and then sent to get everything done as soon as i can afford it.

So today started with cracking some 2litre brakes off the hubs i got with the engine. These hubs also have 2ltr shafts so am gonna use them along with the GSi outer CV's...happy days!



Once that was done i went to vauxhall and collected a huge amount of nuts and bolts (£50 worth) for various parts of the car. (will update with photo 2moz)

So once i got back, i cracked on with taking the engine apart. I've always wanted to do this so was pretty excited. Was a bugger getting everything off, but eventually, the rocker cover, and the valves, springs and lifter head came off. Was a very satisfying occasion. First big step to getting it all sorted and ready to go again.















So all i need now is an engine stand and i can get the sump off and then the bottom end can come apart and i can renew shells, rings and arp the rod bolts. Need my x16xe gone 1st though, need both the space and the cash.

Thats all i did for the day. All i can do for now. Short on money and room, i cant do anything else until the old engine has sold and been collected so i have room to play with in the garage.

Thats all for now folks!
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Old 14-03-2008, 08:39   #10
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Bits...everywhere!

Thurs 13th March

Well i managed to get the rest of the bottom end pulled apart today.

First off was the clutch flywheel and sump. Getting the flywheel off proved a bit difficult but with some help we were able to get it all off.





Once i had these parts off, the next challenge was the water and oil pumps, which...following some swearing and smacking, came off. The main problem with the oil pump was gettin off the crank timing belt pulley. In the end a 3-leg puller and a hammer sorted that problem.

I was quickly making progress and the next job was to get the crank out the block.



So these main bearings were removed following some more swearing and some leverage wit a wooden hammer handle. And then soon after i undid the big-end bearing bolts and everything was then off the crank, allowing me to lift it off!



And once the crank was all out, i was able to (gently) knock the pistons through!



And heres some pics of the bore





So heres the mess i'd made by the end of the day! Was definitely pleased with what i've done, always wanted to do this so i was made up with myself!

Hopefully i can get it all cleaned up, parts renewed and back together ready to run as soon as possible, but am not going to rush...i want a proper job!







Just need to get some diesel and get these parts degreased now...and find a way to jet-wash the block clean.
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Old 14-03-2008, 08:55   #11
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Steam the block, don't jet wash it.

And get some gunk!
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Old 15-03-2008, 23:06   #12
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Ah ok...where can i get a steamer tho??
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Old 15-03-2008, 23:07   #13
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Shiney pistons

Fri 14th & Sat 15th March

Well i've spent two days cleaning up the pistons. Degreasing them using 3-in-1 degreaser and WD-40. Works a treat mixed with some pan scouring pads. Managed to get most of the surface rubbish and carbon.

The idea now is to soak them in a degreasant tub overnight, get them completely shiney, then soak the block itself and the crank, just so its all clean and shiney. I can then make sure its all in good condition and begin putting it all back together.

Heres some pics of the cleaned up pistons anyways!











until next time folks!
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Old 16-03-2008, 10:48   #14
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Looking good mate.
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Old 16-03-2008, 22:51   #15
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cheers! is totting up now tho...realising that im not gonna have it done by PVS due to financial constraints...is gutting, but im willing to wait!
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Old 18-03-2008, 22:26   #16
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quick update in terms of prices i got as im back at work now so practical stuff is limited to weekends off!

Went to vauxhall to price up the bearing shells for main and big end bearings. I expected to get maybe £5-10 a piece...tops. I almost passed out when he said £45...and thats EACH btw!! This was followed by an abrupt "F*** That!!" :lol:

An engine rebuild place in birkenhead quoted me £48+vat for the lot (main and big end shells) which seems much better, forgot to ask bout the piston rings but im hoping the same sort of price tag on them...not the £42 each for the top compression ring vaux gave me.

Have managed to draw up a list of what i need...and iv realised this rebuild is gonna take more spending than i thought. ah well, i hope its worth it in the end!
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Old 19-03-2008, 12:52   #17
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Good Work all the b est with it lad!
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Old 19-03-2008, 14:00   #18
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Good read there fella. Will be a nice car when done.

Just a word of advice on Recaro's. All too often they end up mounted too high on std GM subframes. Try & devise a method to mount them low down or the car wont feel sporty.
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Old 22-03-2008, 10:14   #19
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Quote:
Originally Posted by CraigGreen View Post
Good read there fella. Will be a nice car when done.

Just a word of advice on Recaro's. All too often they end up mounted too high on std GM subframes. Try & devise a method to mount them low down or the car wont feel sporty.
I've got some corbeau subframes from some buckets. They should help them sit lower. Am getting the seats welded onto them properly so there will be minimal amounts of metal making them adapt to each other.

Thats the theory. I actually dont know how they're gonna sit in the end...just hope they arent too high!


Cheers for the interest!
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Old 30-03-2008, 19:19   #20
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No money

Well, due to lack of cash, theres going to be very little happening to this rebuild over the next month. Am expecting my inlet and all the parts are going to be properly cleaned up, but other than that...i'm skint and am putting it on hold to save some money and get some sincere work done on it!

gutted but thats the way these things often go isnt it...
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Old 11-04-2008, 08:24   #21
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Re: GSi 8v build...back on track!

Sun 6th April

Well, the project has taken a quick and very positive turn. Last night (saturday) i went and picked up another engine from Offplot after is saw it offered to someone on here.

It's a c20SEH, but it has had a huge amount of work done to it! It came out of a mk1 astra that was wrecked during a rally, and the spec list is huge!...

Worked Head (Ported and polished etc)
Enim Cam
Kent Springs
RIMFLO valves
FELPRO head gasket
Heavy Duty Followers
Anti Pump Hyd lifters
Lightened and balanced
Piper oil pump
Heavy Duty big end and main bearings

It was putting out the best part of 170bhp at the wheels, and will rev well past what my clocks will show! Cant wait to see how it performs once i've got the carbs on it and its all running as it should!

Heres some pics i managed to get as i was putting it away...








Is going to get some engine paint before it goes in and then im hoping that i can have it in the car by the end of the month! Woo!!

Back on track again!
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Old 11-04-2008, 15:29   #22
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Re: GSi 8v build...

hi mate looks like a good build going on im currently in the stages of rebuilding my 20seh in my dads place in hoylake so only down the road , was thinking about running R1's on mine after the rebuild

the price of the bigend shells is a bit stupid from vauxhall as this is whats wrong on mine but have purchased a 20SE for the botom end and so ive got some spares for the other plans of getting more power from the 20seh

make sure you keep us uptodate
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Old 11-04-2008, 17:47   #23
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Re: GSi 8v build...

looking great as always chris, were u upto at the moment?
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Old 11-04-2008, 22:15   #24
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Re: GSi 8v build...

Quote:
Originally Posted by astra-nige View Post
hi mate looks like a good build going on im currently in the stages of rebuilding my 20seh in my dads place in hoylake so only down the road , was thinking about running R1's on mine after the rebuild

the price of the bigend shells is a bit stupid from vauxhall as this is whats wrong on mine but have purchased a 20SE for the botom end and so ive got some spares for the other plans of getting more power from the 20seh

make sure you keep us uptodate

Ah well when iv got mine sorted i'll pop by and show ya!

Yea the prices are ridiculus!! and i get em cheap too!

Well looking at this new engine i've got, if the figures are correct, you can drag a hell of alot of reliable power outta these engines...
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Old 11-04-2008, 22:17   #25
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Re: GSi 8v build...

Quote:
Originally Posted by lawton View Post
looking great as always chris, were u upto at the moment?
cheers mark!

Well i got the x16 going 2moz, so once thats gone the money can go into getting the strengthening plates and seats sorted.

Then once its back its just a case of getting the mounting kit for the engine, inlet for the carbs and getting it all together and running. I can see the end now!
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