Astravan.. mk4,C20LET, etc..

[elgan]

About to embark on a new project.

Its a 2000 W Council Yellow Astra Van 1.7 DTi.

I have a Phase 2 C20LET from my mk3 Astra Cesaro, it came out of a FSH Calibra etc..

Parts i have collected to date..
Astra GSi F23 Gearbox
Astra GSi Driveshafts
All 3 Gearbox Mounts
Astra GSi Cable GearShifter
Astra GSi 160mph Clocks
New GM C20LET Clutch
Z20LET Driverside Rubber Mount
XEV Bracket and Idlers
Intercooler
Genuine GSi Front Bumper
Coupe Skirts and End Caps
Strut Brace
Various Bolts and Fittings
New Plastic Header Tank
308mm Front Brakes
Irmscher Grill
Boost Guage Pod

Lots of Parts i still require.. But ive got enough to get the engine in. So stage 1 begins soon!

Parts Required
Fuel Tank, Lines, Pump, 5 Stud Set Up, GSi Arch Spats

PM if you can help, pref a sensible travelling distance from south wales. thanks





Some parts in storage.. Ignore nova wing, tubes of mastik, etc

[AK_LET]

Sounds much like the treatment mines getting, Hope it turns out well

[elgan]

any info on which car has the correct or best fuel lines and tank to use for conversion?

[elgan]

got the timing side on engine stripped and 3 holes drilled and tapped. im using the xev mount as pictured.



the 3 holes that need doing to suit..


and said mount..

[elgan]

mount and rollers in place...


and cambelt cover cut to suit..

[Dell Balallan]

Great project! will be watching this one!

[elgan]

With the mount done, i got the gearbox mounted, new GM C20LET clutch.
The gearbox is from a 20k mile Astra GSi.


Pictured is the 3 piece driveshafts from the same car.


I have de greased and pressure washed the engine bay, and its come up pretty well, debating whether to paint this or not before dropping the engine in now..


Here it is all assembled ready to fit..


While waiting for fuel tanks and lines etc.. i got on with a couple of jobs inside the van..

Fit ment of the cable operated Astra GSi gear shifter..


And some 160mph clocks..

Before


After


And into the scrap heap..


So there it is all ready to get on with fitting the engine. Starter and Altenator looms adapted and fitted to engine ready.

[elgan]

Nice but expensive package arrived today..

Genuine new GM shark eyes..


And some OPC Estate Rear Lamps


These will be put away for time being untill its time to get on with some bodywork.

[flatout]

Nice what do you need to know regarding fuel lines fella?

[elgan]

bein a dti van, i want to change the tank and lines. which astra has the best ones suited to the conversion

[Benn]

Nice work, love the rear lights. Cam belt cover looks a bit...

[flatout]

well mine was easy to do tbh, being a 1.8 16v it already had the fuel return and all i had to do was remove the intank fpr and hook up the fuel return from the engine to the one running to the tank, im not certain if there interchangeable tho between hatch's and vans mate but i know they did an injection estate and would guess at those being the same but im not certain.

anything else you need to know fella?

[Ian H]

really liking this so far

[elgan]

changed fuel tank and sorted fuel lines.

could have used the actuall diesel tank so it appears, but would rather run with a new or petrol one to be sure. the fuel tank i had was from a 5dr hatch. tanks are interchangeable from van/estate/hatch etc.

two tanks side by side..


fuel pump in the petrol tank with 'in-tank' fuel regulator. this needs to be removed.


side by side, one pump cover with reg and the replacement one without


i thought i may have needed a better fuel pump than the 1.6 one found in this tank, but a check on epc reveals the part number is the same as x20xev astras, v6 vectras, late calibra turbos etc. so im happy to run with this for now.

[flatout]

Good work


now hurry up and get it fitted

[kevstergsi]

nice work there

[elgan]

Engine is now in and mounted. Gear Cables Connected. Starter and Alternator wire. Clutch Slave. GSi shafts fitted (yes they fit 4 stud hubs). Fitted a new 2.0xev non air con radiator. Heater matrix etc plumbed. Fuel tank and lines fitted.

Waitin on throttle pedal, cable, top hose and header tank.

Just fitted..



Wires tidied..


And clocks removed to mount ecu..


Sparky gets the car thurs, so next to get the intercooler etc on all ready to fire

[elgan]

no picture updates..

the van is with the electrician, and having an exhaust and intercooler pipes done too.

this weekend i managed to buy some gsi arch spats and a gsi leather steering wheel, ready for its return. does anyone know if the wiring is present on a NON audio control car/van for the gsi steering audio controls?

[bucky]

to use steeringwheel audio controls you'd need to change the full dash loom apparntly, then you'll also gain heated seats aircon cruise control electric windows etc if you wanted to.

do the gsi arch spats fit van arches?

[elgan]

yeah, all models apparently.


under the ash tray i got 2 loose plugs, assumed tc and heated seats etc.

im sure ive seen foglamp wires in place ready too.

assumed the looms would have been much the same through the range? soon see when the steering wheel comes off if its all there or not.

[elgan]

Van is back from the electrician... 90% complete.

Remaining to do.. Temp guage, EML Light and Plug, and a few bits and bobs.

Otherwise it starts, drives and stops as it should.

Here it is on its return from the sparky..


While at Welsh Coast Customs in Newport, I had a 2.5" system made from the downpipe back. I had it made with no tailpipe as of yet, i will add it after a rear bumper is sourced and fitted.




I had it pre mot'd on sat, all i need is a couple of bulbs and some attention to rear brakes, so will be taxed and o-t-r beginning of next month..

I didnt want to run around with a blue bumper so ive stuck a std one on for time being..




It is now in full on sleeper mode.. big ass towbar and all. lmao

[elgan]

Electric Window Conversion..

being 2009 i wasnt prepared to deal with winding my windows!

so i got a couple of doors off an astra from the scrap yard and got on with converting mine.

All in all, easy job to do. You need to change the Door looms only and window mechs..

As pictured.





Heres the door stripped of all it didnt need any longer.. (yes the van was 'born' yellow)


And all fitted up incl the donor doors door cards, i also gained chrome interior door handles. Although a different cloth, they dont have holes for the winders

[elgan]

GSi Steering Wheel

Old tired looking plastic wheel..



Simple job, retains original airbag (Although i laterneeded tech 2 to clear an airbag light)

[chip]

Absolutely loving this project, even more so back on the standard bumper, that is just such an amazing sleeper at the moment!

Is it going to PV?

[elgan]

i would if i can get this temp guage and fan business sorted!