Mk4 Astra Saloon Turbo

[Bails VXLR]

Introduced myself on here yesterday anyway thought i would get a build thread set up for my little project, basically..... I was given a totally standard mk4 astra saloon last year from my garandad as a bit of a joke/run around for university but then realised they were quite a rare model. I have ended up actually quite liking it after adding a few mods, and have decided to do somthing a bit crazy. I will be carrying out a full GSI front end Z20LET conversion over the next few weeks.. so anyway here are a few pictures of the car as it is now and the engine to go in, build will be updated on here as and when....







The Z20LET to go in...







Modifications to date:

-Budget coilovers
-Brock B2 Wheels
-colour coded skirts, handles and bumpstrips
-de-badged front grille


Also got a few parts i will still need to complete the conversion these iclude:

-mk4 gsi fuel pump
-mk4 gsi fuel lines
-mk4 gsi front and rear lambda sensors
- full standard exhaust system (not including mani/turbo) this is an area i am still unsure of if anyone has any ideas would be a massive help?... im unsure whether the standard hatch GSI exhaust system is a straight fit onto a saloon model, simply needing the tail pipe extending? or whether the mk4 coupe turbo system would be exactly what i need with it being a longer car like the saloon? will they be the same fitment?

and theres also a few parts that id like to add to the styling of the car as it currently has the worst spec interior possible! these include:

-gsi seats front/rear
-gsi steering wheel
-gsi dash centre console/heater control surround
-gsi trip computer display
-mk4 black 4 door door cards
-black interior carpet

If anyone knows of any of any of these parts available or any information just drop me a message, would be great!

anyway any comments welcome....

Also does anyone know of any other Saloon Turbos?

Thanks Rory.

[bmhb]

Holy crap what happened to that poor gsi! Good project tho I never seen one

[Bails VXLR]

Holy crap what happened to that poor gsi! Good project tho I never seen one

It was a rear end write off, managed to get the whole front of it

[Fow16v]

nice and different, smoked coupe rear lights will fit, and coupe rear spoiler. as for the exhaust im sure the only difference between the gsi and coupe turbo is the backbox which has a longer tail piece, i have a full coupe turbo exhaust here if you want it, turbo back system including both cats centre box and back box. only thing is the tail piece has been chopped off £50 its yours if you need it

[Greydj]

Not your typical cut and shut then

[Kev_G]

cant wait to see this in progress

[scotty GSI]

Cool project! I honestly can not remember the last time i seen a mk4 saloon.

[Th0m45]

looks very nice mate! what alloys are they?

[Bails VXLR]

looks very nice mate! what alloys are they?

Brock B2's mate

[ConnorLake]

looks crap

[M Beirne]

Very nice Astra you don't see very may saloons about.

[Tomo195]

cool looking project, looks smart on those wheels

[novagsix]

very nice project be intresting to see this one come along

[GaryVaux]

I love this!! One of the most original projects ive seen in a while, will look brilliant with the gsi front. coupe turbo skirts and rear bumper would make it

[Bails VXLR]

I love this!! One of the most original projects ive seen in a while, will look brilliant with the gsi front. coupe turbo skirts and rear bumper would make it

cheers mate, yeh im undecided whether to keep the exterior as it as with the suprise factor of the Z20 or go all out with gsi bumper and stuff

[Bails VXLR]

started making some progress on the car over the last couple of days, here are a few pictures..



Old 1.6 nearly out...



Its out



Bay all cleaned up..



Started to strip the Z20..



Coming along nicely



Will be working on it for the next week or so... more updates to come

[ConnorLake]

Who's the sexy man in yellow, it's going to be good when it's done mate

[ConnorLake]

This needs updating

[rad_brad]

Wow really liking that!
Looked really smart to start with, and with the conversion it will have the power to match.

[Bails VXLR]

Right.....Finished the majority of the conversion a few weeks ago but not had the chance to get any pictures up so here they are.. good news is only took a few days to do everything and engine is running perfectly and goes really well! Just got a few very minor electrical problems i am trying to iron out to get 100% completion. i will detail these after the pictures if anyone could offer any ideas/help?

Anyway pictures...

Wiring free and labelled up



Engine out



new timing belt, water pump etc..



Done away with aircon (added weight )... Genuine Vaux Aircon delete kit fitted



In place..





getting there...



Bit of wiring to sort out



GSI brake setup



Bay back together





GSI Dash loom and clocks in (just 30k on them )



first purchase



pretty much back together, got hold of some cheap 5 stud vectra wheels for the time being on the front until i can get some new 5 stud brock b2's.






So thats how it stands now, running great engine is brilliant and very pleased everything went so smoothly, had a few little problems but all fixed now. However as said i still have a few electrical issues one being the ABS and traction control lights on as i have the standard rear axle and therefore no rear hub sensors. But obviously i need to eliminate these lights for MOT purposes.

Also eveything works electrically that i would expect to work other than the electric windows?? which is a bit of a pain since i removed the aircon!! has anyone noticed this when swapping the GSI dash loom over to a lesser model (are the electric windows wired differently on those?) will i need GSI door wiring harnesses? I simply connected the dash loom to the rest of the car at the green block connector as shown below on the gsi in the passenger footwell (below), and the blue one was left disconnected as i believe this is for side airbags (which i do not have), but i am only pressuming this is what that is for?



Any info on this would be great!

I am also still after the Multi function display for centre console if anyone has a good condition one going?

Last thing to go in will be the GSI dash as soon as i have all the wiring 100% sorted.

Any comments welcome! Cheers Rory.

[Tom Williams]

My first thought on the windows is that the ring on the brown wire that is in the middle of the picture needs to be connected to the bolt in the picture - is this connected on your car?

[Bails VXLR]

My first thought on the windows is that the ring on the brown wire that is in the middle of the picture needs to be connected to the bolt in the picture - is this connected on your car?

cheers mate, yeh thats connected up in mine picture was from when i was removing it

[Th0m45]

progress is good! really liking this build! you definately putting broc b2's back on?

[mozz22]

hi mate great project, looking really good, just out of interest how much you pay for the gsi front end?

[the saloonatic]

good to see another mk4 saloon owner on here cars lookin good, was considering doing this conversion to mine a while back but decided doing something different instead.