another mk4 astra project C20XE
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Thread: another mk4 astra project C20XE

  1. #1
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    another mk4 astra project C20XE

    right o heres the latest project had it about a month now not really done anything as got it with a wrecked engine

    its standard apart from rear tinted windows

    its a 2004 sxi model and usually comes with a 1.6 16v z16xep engine

    came with coupe leathers ( also got rid of the playboy seatbelt cover things lol)

    also came with a full sound system including upgraded front and back speakers

    heres the pics







    the sound system

    vibe cbrs12 twin evos

    vibe deep black box bass 5

    and full vibe black air 5 component set


    so thats what i got it with i swapped it for a tubby rep spectral blue cavy dippy

    so now just to add my little mods

    something ive done with all my cars is angel eyes its a personal touch

    i bought them off a member on AOC for £33 in need of repair

    so recivied them threw the post one of the lenses kind of melted should i say and the other unit was cracked.so ditched the lenses for the one off the astra and cut one of the units and plastic welded it back to gether and heres the finished result

    also had 2 sets of hids sitting about i got cheap













    a few pics of the lights fitted and its new home untill i get the engine sorted
    Last edited by gilly-06; 08-03-2011 at 20:26.

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  3. #2
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    Re: another mk4 astra project

    with the lights fitted







    also got a badgless grill to put on still sitting in the box lol

  4. #3
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    Re: another mk4 astra project

    right with the engine bay empty it was time to turn to what do i put in it

    options were

    1. 1.7td isuzu engine that sitting under the blue cover in a cav £0

    2. the same engine that was in it 1.6 16v £400

    3.2.0 16v redtop complete car £300 and with the option of paying it up off a mate


    so this is the result

    so arrived at my mates on saturday morning house with the car sitting in his garden awaiting to be stripped
    before













    xe in my cav boot lol







    and thanks to my mate camy brought the engine crane over on the Sunday at 3pm thanks mate

    had the engine in by around 6pm with it all mated up to the gearbox then it was getting dark









    yesterday i went back to my mates to get a few more parts off the cav (mainly spares for ours lol )

    so got a 4-2-1 full stainless steel exhaust and fuel pump (not sure if the one in the Astra will be ok for the job )

    f16 gearbox

    accelerator cable

    plugs off the loom for the ones that plug in beside the ecu

    and a load of other parts

    today i set about the wiring just matched colour for colour on the black and green plug with loom sitting in front of the fuse box (empty bay pic ) and joined them up to there quite a few wires left

    only thing i couldn't figure out was the fuel pump wire in the car loom ( found the relay in the fuse box so pulled the fuse out and stuck the wire into the blue and red thick wire in there)

    i decided to use the Astra starter and alternator wiring loom as it was basically plug and play


    and hey presto first turn of the key and the engine started first time to my surprise with out afm connected or down-pipe or any coolant connected but was only run for a breif 2/3 seconds

    decided to put the ecu in the car over night as i dont like it sitting out in damp weather will i can seal it up and find a suitable place to put it

    also got the down pipe connected and cav rad in place and pipes joined but not tightened up yet

    here how i left it before i closed the bonnet


  5. #4
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    Re: another mk4 astra project

    the main part thats needed now is the engine mount not sure what folk have used but thinking a corsa redtop conversion mount would be the best thing to use

    whats everyone els used ??

    thanks for taking the time to read

    gilly-06

  6. #5
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    Re: another mk4 astra project

    Thats going to be good at the traffic lights! Bye Bye

  7. #6
    Moderator / Memberships Astra Dan's Avatar
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    Re: another mk4 astra project

    The Astras pump will be fine for the XE. Well done on the starting and charging loom. Many people, even long term members, don't realise the extra work they make for themselves by cutting that loom apart. As you say, it just swaps from one engine to the other. The temp gauge won't work without the 1.6's sensor and ECU to drive the clocks I think.
    There is just room to squeeze the XE ecu behind the clocks, after you've cut the hole in the bulkhead for it.
    They're there, in their room.

  8. #7
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    Re: another mk4 astra project

    Quote Originally Posted by badboysracing69 View Post
    Thats going to be good at the traffic lights! Bye Bye
    im not much of a racer lol i know a decent amount about the redtops plus less hassle than the newer engines lol

    Quote Originally Posted by Astra Dan View Post
    The Astras pump will be fine for the XE. Well done on the starting and charging loom. Many people, even long term members, don't realise the extra work they make for themselves by cutting that loom apart. As you say, it just swaps from one engine to the other. The temp gauge won't work without the 1.6's sensor and ECU to drive the clocks I think.
    There is just room to squeeze the XE ecu behind the clocks, after you've cut the hole in the bulkhead for it.
    yeah i thought there might have been problems with the starter thinking it wouldnt turn over because the engine ecu wasnt inplace but it turned over ok

    and thanks for the advice about the astra pump thats another thing i dont need to worry about lol and good idea about the ecu keeps it out of the damp didnt really want to mount it outside

  9. #8
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    Re: another mk4 astra project

    todays progress



    got the rad all plumbed in and the astra fan connected and cable tied to the rad



    all the coolant plumbed in



    airbox all set up again



    fuel pipes joined and secured



    exhaust mated up (still blowing a little but have to add a cat so will be coming off to get the cat pipe sorted)



    accelerator cable inplace



    changed the alloys for the ones on my cdx



    and added the debaged grill from egay



    still to do



    get accelerator pedal + fit



    relocate ecu



    add battery tray



    buy /make engine mount



    do a proper job on the wiring after ive relocated the ecu as the wires will have to go to the plugs beside the ecu



    and thats about it



    heres the pics






  10. #9
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    Re: another mk4 astra project

    have you got the engine mount sorted mate? I bought an astra mk4 with a c20xe engine already converted and it looks like they have used a corsa conversion mount welded to the chassi leg. i can send you a picture if you want?
    Want good quality mirror finish smoked rear lights for you car? drop me a pm.

  11. #10
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    Re: another mk4 astra project

    pictures would be brilliant mate im making up a temp mount for now using a 2.0 8v engine mount and making my own rubber mount using stickaflex untill i can get some cash together to buy one


    cheers and much appreciated


    also started moving the ecu to inside the car today want it to look like its standard going round the strut mount area and thew the bulk head that way just the hole to cut to inside the car

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    Re: another mk4 astra project

    i used the cam side mount from an x20xev astra, you have to drill and re-tap the 3 holes on the side of the block behind the inner cam cover, but as you now have the engine in the car allready your going to have a job with that..

    on a previous conversion i used the corsa mount setup and welded to the chasis leg but i made this myself

    have a read through my diary it may interest you

    Astra G c20xe Project (very picture heavy)
    ASTRA G C20XE,BUILT NOT BOUGHT... GD DEVELOPMENTS

  13. #12
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    Re: another mk4 astra project

    funny enough iwas just having a look at your thread brilliant build

  14. #13
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    Re: another mk4 astra project

    well thats the ecu placed in the car went the same route as the cavy went and in threw the bulkhead found all the wiring inside the car beside the fuse box only thing i had to do was find the fuel wire at the old bulk head plug and cut it and extend it to the drivers side and joined it there

    im keeping the switched live + oil level(front of sump) in the bay as they connect to a sep plug so im happy keeping it in there saves anymore hassle trying to re route them threw the bulk head

    got some interior bits done between the last few weeks

    got blue led conversion on the mfd and headlight switch and clocks

    also done the heater controls but due to them having a orange tint to the facia i had to go with that but i like it

    then i got some white festoon led bulbs for the interior lights as i dont like the blue you cant see a thing with them

    got a few other b sit sorted my sterio in and ran some more audio cable for the front and rear speaker amps

    and my external base boost usb wire and aux cable in the centre cubby hole part

    heres a pic of the centre consol


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    Thumbs up Re: another mk4 astra project C20XE

    hi buddy

    how did you get your heater control so bright? what did you use to do it?
    looks good

    Nice project . bet you cant wait till your engines all complete

  16. #15
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    Re: another mk4 astra project C20XE

    i used 19 leds lol was prity fiddley to do but worth it its not as bright at the pic itsnot so in your face lol

    yeah everythings virtually finished

    few tings i need to do and get is

    finish the engine mount

    get an accellerator pedal

    and fit an external temp guage and

    and it should be ready for the road

    oh also still cant seem to get the power steering working for some reason

  17. #16
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    Re: another mk4 astra project C20XE

    hi buddy. have you any pics or how to,s on how you did your led conversions. its someting i want to do. but i dont know how to get the control knobs lit up.

    or if you could explain what you did please

    my email is chrisgs23@yahoo.co.uk

    would be a huge help

    chris

  18. #17
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    Re: another mk4 astra project C20XE

    well long and coming update sorry guys

    got married in march 26th then in may decided to move to newcastle so the project halted there

    finally about 2 months ago i got it transported up (shiply) for £120 which aint bad

    so the work commenced down here trying to get it sorted

    first thing i dont was lower it on 60mm rear and 40mm (cav fronts because of the engine thought it would be better)

    put all new brakes on and started on the exhaust

    i bought av6 vectra estate backbox off a friend (that was too big )

    so then decided to cut the rear wheel well out and do a centre exit


    because the temp guage wasnt working i decided to go the route of the digi dash then everything works basically ive wired the speedo up to the abs and it only seems to be 2mph out using them speed signs at the side of the road



    some pics









    its mot'd and tax'd now im glad i kept it

    i have a cat back turbo exhaust to put on it and im going to put the exhaust back to the left hand side not too keen on it in the middle

  19. #18
    Scottish Regional Co-ordinator/MIGWeb Moderator GaryVaux's Avatar
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    Re: another mk4 astra project C20XE

    The wiring/ecu etc of newer cars confuses me, well done figuring it all out.

    New wheels look much better

  20. #19
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    Re: another mk4 astra project C20XE

    i have plenty of Patience for wiring lol.decided not to keep the astra ecu couldnt be fussed with all hassle of 2 ecu's looks much neater under the bonnet and i decided to use the cav rad and made my own wiring up for the fan

    only problem i stumbled upon was the electric steering pump trying to get it working its working just now but i have to rewire it to the blue/ white alternator wire

  21. #20
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    Re: another mk4 astra project C20XE

    i wired my ps to the alt and it was perfect

  22. #21
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    Re: another mk4 astra project C20XE

    read this as i really wanted too know about the engine mount as i was going to use a corsa mount but going to try drilling the holes out on the block as its already a x20xev astra! result
    INSTALLING SUMMER... ████████░░░░░░░░44% DONE. Installation failed.
    404 error: Season not found.

  23. #22
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    Re: another mk4 astra project C20XE

    i used the corsa mount set up didnt wanna chance going threw the block + if i need to do a head gasket change or anything its easier

  24. #23
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    Re: another mk4 astra project C20XE

    Quote Originally Posted by crombievts View Post
    i wired my ps to the alt and it was perfect
    yeah thats my plan mate but i couldnt get it to work at all then found the wire in the ecu harness

  25. #24
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    Re: another mk4 astra project C20XE

    Could you get me a pic of your mount setup mate?
    INSTALLING SUMMER... ████████░░░░░░░░44% DONE. Installation failed.
    404 error: Season not found.

  26. #25
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    Re: another mk4 astra project C20XE

    just using the corsa b mount set up mate


    sorted a few annoying bits on the astra like the electric steering

    i have a zlet middle section and back box to put on as i'd rather have a more or less standard system just need the flange the otherside of the cat and weld that on to the redtop downpipe


    also thinking on fitting a f28 box aswell i know i need to use a f23 rear gearbox mount and custom front mount (was thinking of using corsa/nova mount kit )

    and i also need to use an f18 hydraulic cylinder and pipe for the clutch


    ive heard the cali/cav equal length shafts are the best to use do these fit the astra hubs ok ??


    i need to change engines anyways as some one said low oil pressure so hopefully the mrs will let me transfer the cav lump in to it and then rebuild the one out the astra

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