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Old 26-05-2008, 20:58   2 links from elsewhere to this Post. Click to view. #1
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MK4 Astra GSi

Thought about time I started a thread on here for my GSi.

Right here we go, another MK4 GSi and hopefully 3 times a charm with this being the third MK4 GSi that Ive owned.

The plan is simple, I wanted a car to fulfil areas:
- Track use
- Long distance road use

With this is mind I decided the GSi was the perfect choice and had always missed my previous cars. With the car being built to cover 2 very different areas a few compromises have to be made, (for example a stripped out car is not going to be a pleasure on long journeys, but likewise running standard soft suspension is no use for track days).

So after setting the basics down the search was on for the right car. 3 weeks of searching (I swear thats a record as far as Im concerned), and cars were either the wrong colour, previously owned by a chav or just too expensive for what they were. At this point I was really having second thoughts on the GSi but at the last minute E-bay came to the rescue. A Black GSi, totally standard, full service history and sitting with not a lot of time to go at a low price. A cheeky bid later and I was on my way to owning it.
A few calls with the owner confirmed all I wanted to know and with that it was an 800mile round trip to Cambridgeshire to collect the new car.

Couple of pictures on the way home:







It did have the obligatory dump valve which has since been removed and as an added bonus came with an Irmscher grille & some sort of HID kit:



Once home it was time for a basic check around the car and some basic service items. The initial plan had been to paint the car white but once home the paint on the car (minus the front bumper) really is in too good condition to warrant painting. It did have a few minor dents on 1 or 2 panels, but a quick visit from Dentcentral soon had these removed.
The tyres on the car weree also a random mix, with random amounts of wear so first job was to replace these with 4x Yoko Parada.

Once the service items were done it was time for Stage1 - suspension.
This consists of Bilstein B6 dampers and an Eibach -45/30 spring kit.
There is also a Whiteline rear anti roll bar kit (this is currently awaiting part of the fitting kit to arrive to allow fitment), and Whiteline front anti-roll bar (this is waiting for the subframe to be fitted but more on that later).

Few in profgress pictures:





Stage 2 - Engine

Now the idea had been to go the usual route of VXR turbo, exhaust etc. etc. however, whilst browsing E-bay again I came across a 15,000mile Astra VXR being broken for spares. The initial enquiry was made to the seller regarding the front brakes, but a few calls and a 700mile round trip later:



I managed to pick up the Z20LEH, M32 6-speed gearbox, complete front & rear brake setup.

The front & rear brake setup have now been fitted to the car and have bedded in nicely.

No when inspecting the car I found a couple of areas of the exhaust were looking dubious, not too discouraging as it was due to come off regardless. The AOC Milltek group buy was running at the same time so I went for a Sports cat & cat back system (had previously purchased a pre-cat from LMF).

Again this was fitted on, Id like to say this went on smoothly and hassle free, but quite honestly it didnt and required replacement parts to be sent out in order to eventually get it sorted.

So a few pictures of the car as it stands:







So the cars spec as it currenty stands

Engine:
Magnex pre-cat
Milltek 200 cell sports cat
Milltek cat-back system
De-restricted airbox

Suspension:
Bilstein B6 dampers
Eibach -45mm springs front
Eibach -30mm springs rear

Brakes:
VXR front discs & calipers
VXR rear discs & calipers

Random parts:
Irmscher X-hatch grille
Irmscher chrome heater dial surrounds
Some random HID kit


Parts awaiting fitment:
Z20LEH
M32 gearbox with Quaiffe LSD
Courtenay Front Mounted Intercooler
Courtenay silicone pipework

Ive yet to decide what spec the engine will finally run or what software it will run with.

Quick thanks to Courtenay Sport, LMF & dannysport for their help thus far.
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Old 26-05-2008, 21:03   #2
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Re: MK4 Astra GSi

VXR mk4. Nice!
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Old 26-05-2008, 21:03   #3
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Re: MK4 Astra GSi

Looks very nice.
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Old 26-05-2008, 21:04   #4
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Re: MK4 Astra GSi

That was where I was upto on Astra-Sport.

New update.
I managed to source a Quaiffe diff via LMF and had a mate fir that into the M32 box ready for fitting to the car. Now I had thought aboutdoing the engine/box swap myself, but quite honestly dont have the time or inclination to do it myself at the moment. So 4weeks back a few pm;s and telephone calls were excahnged with GMAN on Astra-Sport. After some discussions a plan was set and a few days later the GSi and the Omega ladden up with bits headed down to REading for the transplant.
So 3 weeks later and the call came to collect the car. Since going down its had the follwong:

Z20LEH fitted, M32 box fitted, Whiteline front anti-roll bar fitted.
Also prior to going down I had fitted a new radiator & Courtenay FMIC.

Ig thansk to GMAN, anyone looking to have anything similar done I cant recommend him enough.

Now the cars back I have a few jobs to do this week:

-fit the new airbox setup
-sort the ariel for the radio
-fit some new front brake pads
-Actaully get around to fitting the adjustable rear Whiteline ARB

from there I need to look at what map to go for and that should pretty much see the spec of the car for the summer. Aiming to have it finished within the next few weeks as we are off to the Ring at the begining of July.
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Old 26-05-2008, 22:04   #5
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Re: MK4 Astra GSi

Nice mate, what about the MK3s?
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Old 26-05-2008, 22:33   #6
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Re: MK4 Astra GSi

nice work fella, ive had my eye on another mk4 gsi for a while, prices are dropping fast which is good!
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Old 27-05-2008, 09:03   #7
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Re: MK4 Astra GSi

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Originally Posted by novacabrio View Post
Nice mate, what about the MK3s?
MK3;s are all sold chap. Unfortunately the white one was one problem after another, that attached with a distinct lack of enthusiasm for the car & someone offering the right money to buy it I decided to cut the losses and move on. With the MK4 GSi and ST200 Ive more than enough to keep busy
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Old 27-05-2008, 16:32   #8
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Re: MK4 Astra GSi

Beast! One to watch. One to wait for when it comes up for sale too!
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Old 27-05-2008, 19:40   #9
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Re: MK4 Astra GSi

Got a few teedious jobs done:

Nearside washer jet has never worked managed....eventually, to unblok it.

Since getting it back the HID;s have never worked. Did a bit of dismantling and routing around (the previous owner mounted the ballasts in fecking awkward places), found there were two rpoblems, one balast had the plug in bak to front, the other had the earth cable missing. Sorted.

Main one was the running problem. Its had a slight miss-fire problem under load. Occasionally at around 4krpm it would die then come back, then up around 5k-5.5krpm its was stuttering with a little backfire almost like one plug was breaking down/spark bowing out. So bought some new VXR plugs at work today and put them in tonight. After taking the first plug out I was confident that was the problem as the plug was ****ed......as were the remaining 3 that came out.
By the looks of it the tops of the plugs had been sitting in water for a bit, presumably whilst the car it came out sat in storage waiting to be auctioned. So one set of new plugs later and the car runs smooth as you like, no splutters or miss-fires.

Also had my Regal alloy bottom pulley arrive today along with the Powerflex front mount bush. Hopefully get those fitted on Thursday when Im off along with a few other parts.
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Old 28-05-2008, 05:34   #10
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Re: MK4 Astra GSi

Nice, if i was to have bought and built a mk4 astra this is the sort of mods i would have made to it.

Out of interest are you running the VXR engine loom or the Z20LET loom?
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Old 28-05-2008, 10:35   #11
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Re: MK4 Astra GSi

Craig - Ive gone through my TimP stage and will be keeping this for a while.

Rick - it runs ZLET loom & ecu as teh VXR runs a CAN system.
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Old 07-06-2008, 09:05   #12
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Re: MK4 Astra GSi

Small update:

Thursday was spent rectifying the radio problem. Unfortunately Billy Bling and his mates had fitted an aftermarket headunit.....badly. As a result they hd broken the areil connector which meant my nice new Alpine unit has had no radio reception for the last 2 months. With a day off it was time to replace the short front section of cable. Quick trip to the local breakers yard and £1 later I had said cable. 30min of interior stripping and re-assemble later and I now how reception. Sorted.

Friday I cracked out tech2 to check what fault codes were present to see if there was any clue to why it was cutting boost at 4krpm. Sure enough there was a fault code for a boost control solenoid. 10minutes later, a new solenoid and a quick drive and the car is cured, nice and smooth right round to the red line.

Finally, yesterday I had my Parrot hands free kit fitted with the screen located under the radio.
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Old 07-06-2008, 10:27   #13
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Re: MK4 Astra GSi

Excellent Dave - very satisfying rectifying someone else bodge or **** up.
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Old 21-06-2008, 14:35   #14
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Re: MK4 Astra GSi

Well a week past today with the help of Turbodave and tall mate, the GSi was dropped off at MPG in middlewich.
The car had been back from G MAN for around 3weeks so happy that the engine etc. was running sweetly it was time to get some more power.

So a week later and it was back on the M6 with Turbodave to go pick the car up. Long arse day again with around a 4-hour drive eachway, not helped by and accident south bound on the M6 just outside Warrington which resulted in a tailback North bound due to rubber neckers.

Anyway, car now runs EDS P3.5 software (with a switch), Regal inlet cam, VXR injectors, VXR airflow meter, Regal alloy bottom pulley, modified airbox setup, Vectra C inlet, rocker cover breather & Christ Astely water hoses.
As they had the car and times getting short before going to the ring I also had them sort the air con (was needing re-gassed after the engine swap & the air con fan was ****ed), and fit the Whiteline RARB (purely because I couldnt be arsed).

Hoping to get the car on the rollers some point this week and see what its running.

All in an awesome service from MPG. Very very happy with the work that was carried out and the service that was received, definately recommended.


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Old 21-06-2008, 14:42   #15
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Re: MK4 Astra GSi

Looking nice Dave, is this your daily drive? Never seen it around.
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Old 29-06-2008, 11:28   #16
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Re: MK4 Astra GSi

Keith - has only started to be used as a daily driver the last week or so as Ive now takent eh ST200 off the road.

Tonight was speant changing the fuel pump.

Out with the old



And in the the new FSE pump, flows 2.6litres a minute (big big thank you to Courtenay Sport for bending over backwards to supply this quickly).



New and old



Only took an hour or so to remove the old one, modify the pump cradle and re-fit the new pump.
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Old 29-06-2008, 11:39   #17
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Re: MK4 Astra GSi

Nice one dave, good to see its all coming together nicely, will you be taking this to the ring or the st?
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Old 29-06-2008, 13:21   #18
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Re: MK4 Astra GSi

Quote:
Originally Posted by Dexy View Post
Nice one dave, good to see its all coming together nicely, will you be taking this to the ring or the st?
Taking this to the Ring, ST is off the road & has been raped off its wheels for the Astra:

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Old 29-06-2008, 14:41   #19
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Re: MK4 Astra GSi

Just don't leave it on the forecourt overnight!

Any sign of the Corsa VXR, or is it a forgotten case?

Astra looks good.
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Old 29-06-2008, 14:53   #20
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Re: MK4 Astra GSi

Looking very nice dave, very nice.
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Old 29-06-2008, 15:15   #21
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Re: MK4 Astra GSi

Oh the st wheels suit that dave, very nice.
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Old 29-06-2008, 16:12   #22
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Re: MK4 Astra GSi

Quote:
Originally Posted by Dave Dempsey View Post

Those wheels do look great on there... the ring? Nice have fun..
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Old 30-06-2008, 14:21   #23
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Re: MK4 Astra GSi

Good progress Dave. The ST speedlines look ace on it.

I'm interested in the VXR engine swap & issues with the loom ECU etc... Its essentially the LEH block & g/box with the existing Z-LET loom & ECU but obviously remapped to make best use of the VXR turbo, FMIC etc?

Did the mkV shafts & M32 box all hook up fine with no worries on the mkIV?
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Old 01-07-2008, 20:09   #24
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Re: MK4 Astra GSi

Perfect matey!

Much involved in fitted the VXR engine?
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Old 11-07-2008, 18:13   #25
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Re: MK4 Astra GSi

how is it on fuel and rev range with the 6 speed box out of interest?
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