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Discussion Starter #1 (Edited)
I've copied this diary from another forum where I have it hosted as I thought I'd share it on here.



I originally bought my Vauxhall Vectra SuperTouring 200 #0005 in 2001 and it was used as my daily driver for a year before becoming a second car. In 2004 a long hibernation began after the purchase of my first house and it was safely stored away in the integral heated garage for 5 years. This diary begins in 2009 and I'll date each copied post.

I won't go into the ST200 in depth as it's been covered so many times and there are lots of myths floating about surrounding this particular model but a brief overview for those who don't know. Vauxhall originally commissioned a limited run of 50 but only 37 official saloons plus an unofficial estate were built with a total model run of only 38. Each vehicle having an individual build plaque affixed to the front of the ashtray. They were pre-registered as SuperTouring 24v but some latter conversions began as SRi before heading to MSD (Motor Sports Developments) for the full conversion to an ST200. They were available in white, red, black and silver with the estate being blue. The full official conversion to an ST200 included a lower final drive 4.45:1, AP front brake kit, X30XE inlet cams, 17" Speedline Mistral 4 wheels including spare, Steinmetz side skirts, AP Suretrac LSD, Koni suspension & Recaro front sports seats with embroidered Eurosport motif.
 

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Discussion Starter #2
17 May 2009

As most of you will know it's been in hibernation since Sept '04 due to me spending all my spare time and money on my Astra mk2 GTE.

Started doing a few bits and pieces to the ST200 over the last few months in preparation for it coming out for Billing later this year. I've now took the decision to convert all my minor exterior mods to standard including brand new series 1 front lights and grills as well as tail lights and red spoiler brake light. I've also got a boot full of other goodies I'll be adding over next Winter.

Old front end


How it still looks two months later


Brand new F1's and the rims are still being stored in the living room


Brand new series 1 front lights



Headlight loom plugs converted back to series 1, plug on the right


Also got myself a LUK clutch kit which has covered about 30 miles and a Courtenay billet flywheel which had about 100 mile use. Planning on removing the box to get these fitted next Winter so thought I better get myself a brand new clutch master and slave cylinder for when this happens


I'll add some more updates as and when but the next job is the timing kit which I should be doing today but spending my time watching all the ITV4 BTCC coverage. Never done a V6 belt before but I'm always up for a challenge and know the theory behind it so bring it on.
 

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Discussion Starter #3
23 May 2009

Spent some time yesterday on the Veccy as I planned on changing the timing belt, enjoy the pics.

Stripping all the various bits and pieces off prior to removing the cover, can’t believe how much you have the remove as the C20XE as so much easier.



Cam locks in place.


Had a rummage in my Vec boot and found a brand new auxiliary belt, old one was showing slight signs of cracking.


Also found the timing belt kit I purchased for £30 from Billing a few years ago.



My old crank pulley is cast and heavy so I have got a later spec 3.2 pressed pulley which is fair bit lighter to replace it, it’s a straight swap.




Wasn’t planning on doing the water pump but then found I had a brand new one also stashed in my boot and as I was at the stage where it could be replaced it was silly not to.


Top tensioner backplate in my kit was for a later spec, I believe post ’98 V6, so I swapped over the tensioners as my backplate was is tip top condition. Can you spot the difference below?




Flushed out the coolant system, then removed the water pump before flushing it out once more. Flooded the front of the garage so had to sweep it out.




Old pump had a very small amount of plan and once removed felt tight so glad I had a replacement.


New water pump bolted in place and left to cure over night before adding coolant as I added extra silicone to the rubber seal.

 

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Discussion Starter #4
24 May 2009

After a bit a head scratching yesterday I've now discovered that I have a later spec timing kit as the timing marks for the front head are 5 teeth further along the belt. Going to keep this kit for the 3.0 I'm sticking in Amanda's Astra mk3 later this year and get an early timing kit next week for my Vec.

Had a poke about underside and noticed the sump is leaking along the front edge as there are no visible leaks form the oil cooler unions or anywhere above the sump. Another job to do before the Milltek front pipes go on.
 

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Discussion Starter #5
26 May 2009

Did some more on the ST200 today and did a spot of research into the timing kits available and purchased a Conti kit for the grand total of £62, a bargain from SAF. These kits are top quality and use the OE rollers and tensioners. The kit details below are the early Vectra V6 version.





First time I’ve done a X25XE and it was as easy as 1 2 3 as I had the correct locking tools and a print out from TIS to work from.


While I had the air box removed I marked the lower section and did a small mod to the side which won’t suck in any hot air as the chassis hole is a direct cold air feed from behind the bumper. I removed the light loom from it’s clip to give better cold air feed.



That’s the belt changed and water pump all done and back together.


Also picked up a genuine Vauxhall sump gasket from my local dealer today.


Sump leak was along the front and sides. Lucky it doesn’t look like the rear crank seal was leaking but I’ll inspect that closer when I get the box removed over next Winter.


 

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Discussion Starter #6
2 June 2009

Sump and fitting bolts cleaned and refitted.






Also dug out my Milltek front pipes and began fitting them but they are very tight and I had a battle getting the rear to fit, still wrestling with the front as it’s refusing to slide into the manifold.



Standard system adaptor on the right and Milltek system on the left, should be good for a few ponies.



Purchased some SupraPro Mikalor clamps for the exhaust as they give a better all-round clamping force, top row. Milltek clamps are stainless, bottom row, but I’m happier using the Mikalor.



New OE downpipe gaskets.



New Bosch lambdas, I need to extend the front mounted one as the cable is longer.


 

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Discussion Starter #7
13 June 2009

Managed to check my pistons for movement last weekend and I’m please to say they are all free with only 3 of the in-board pistons slightly stiffer than the rest. They have always been like that but I am planning on refurbing my spare calipers over Winter and fitting them next year.
Used a spare set of pads to wedge one side while I worked on the other with Amanda pressing the brake pedal for me.


After a lot of frustration and swearing I had to open up the o/s front pipe flange mounting hole by 1mm to get the front pipe to slot into the manifold. Milltek down pipes now bolted into position so I can crack on with fitting the rest of the system this afternoon.




A friend on VVOC dropped me a PM a few months ago asking if I knew anyone who might want his old genuine AP 1 pieces disks off his Vec as he’s now gone with a bell and rotor setup. After he said they had only covered 4K I snapped them up and collected them from PVS last week. The disks are in tip top condition and after I have cleaned and painted the centres they will look like new. They still measure 32mm wide and have next to no wear at all. Just means I can pop my brand spanking new disks in my loft with all my other spares.



Tried to show below just how big they are, bear in mind I have what are classed as medium sized hands.
 

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Discussion Starter #8
14 June 2009

Got my disks painted with satin black high temp paint and fitted them today also got the lambda sensors fitted.





Finally dug out my Milltek system and unpacked it in my living room, it’s been sitting in my Veccy boot for about 2 years. Will be fitting it with brand new OE mounting rubbers later this week. I’m very very impressed with the build quality, just hope it goes on easier than the down pipes did. It’s a 2.5” diameter system all the way through so should give decent gains coupled with the Milltek down pipes and 100 cell sports cat.

 

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Discussion Starter #9
16 June 2009

New exhaust hanger rubbers and the metal clip things that go on the chassis stubs.


Headlights and indicators now fitted.


 

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Discussion Starter #10
18 June 2009

After a lot of laying around on my back last night I finally got the Milltek centre section bolted on and have jacked up the rear in readiness to install the remainder of the system this evening. No pics as it’s a little tight under there.

Removed the alloy mesh from the front bumper and installed the OE lower grill as I decided against the Irmscher item I have.

To install the mesh I drilled the tabs and used zip-ties and on the sides I glued tabs in place with a hole and used garden twin





New grill installed and part number if anyone wants it




Just for Rigger as I loved his comment at PVS I then decided to dump yet more stuff in the living room so there is now my wheels, exhaust, old series 2 headlights and my front bumper in there now. Just glad Amanda doesn’t mind…too much and if anyone asks again no she doesn't have a sister who will let you use the living room as a car parts store just a brother if your that way inclined.

 

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Discussion Starter #11
19 June 2009

Rest of the exhaust system is now fitted and I’m really please with it. All went on without any headaches.
It’s a tad short and doesn’t stick out much but follows the line of the rear skirt nicely.



These are the gay VXR print that is on both tail pipes, it’ll be getting polished off without delay as soon as it’s out the garage.



Looks like it hangs low but it’s all nicely tucked up as far as it’ll go.



Changed the break fluid, filled it with oil and half refitted the front bumper. I’m getting all excited now as I’m nearly there.

 

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Discussion Starter #12
21 June 2009

Had an evening off my Vec on Friday so cracked on with it yesterday.
Checked over the rear calipers and copper greased them, filled with coolant and then turned it over after removing the fuel pump relays and DIS pack loom plug. I did this just the make sure I had the time correct and I didn’t hear anything metal to metal. Then I fired her up and all was good but I had what I believed to be a noisy
tappet on the front bank near cylinder no.6, although it could have been the injector not quite sure yet. Checked over the exhaust for leaks and all was well so I’m happy with that. Had it running for a while so the coolant could bleed through and the rad fan kicked in a few times. Then turned it off, refitted the wheels and sat it back on all fours.



Then decided to fit the OE red spoiler break lights and remove the Irmscher clear item I had fitted.



Also removed my clear modded, red bits removed, tail lights and fit the brand new OE items I got from Billing last year. The clear lights got through the last MOT in ’04 as I used special ‘silver’ bulbs like the indicator versions you can get as pictured below.





Just to prove the last time it was on the road as the old tax disc is still fitted.



Back to bed until tomorrow as a mate is popping round to reset the airbag light as I had a faulty squib I replaced in mid ’04 but never had it reset.



Some random Vectra related pictures I have hanging in my garage :)





Hoping to get her MOT'd next Saturday and then she’s all ready for Billing after a good polish and spruce up.
 

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Discussion Starter #13
26 June 2009

Mate popped round the other day and reset my airbag light after I swapped the ECU as the original had a fault. Also got all the historic EML fault codes cleared so it's now ready for an MOT next Wednesday so fingers crossed it gets through.

Here's a little vid I took when I had it running the other week, new zorst sounds rather nice :)

Click for video
 

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Discussion Starter #14
2 July 2009

I now have a fully road legal ST200 #0005 as it passed the MOT yesterday with no advisories.Cover 9 miles in it so it just needs a wash and polish and it's all ready for Billing :)

I'll update this build diary as and when I do things to the ST200. Winter plans are to install the billet flywheel, new clutch and replace the master and slave cylinders.
 

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Discussion Starter #15
14 July 2009

Had my Vec aircon re-gassed on Friday morning prior to my drive down to Billing. Did a bit of hunting round for a decent place to have it done and decided to go to a specialist. Found a company about 2 miles from where I live called Lake Refrigeration & Air Conditioning, click the company name for their website and contact details. They are based in Watnall and are about a mile form M1 J26 in Nottingham. I popped to their unit for 08:30, had a quick chat with Steven Wood who runs the company and 25 mins later the inside of my car was as cold as the North Pole. As my car has been in storage for a number of years I had next to no gas in my system but luckily I had no leaks. So the old gas was sucked out and 900 grams was added. Job done and they are very very cheap if you don’t want a receipt. They do offer a mobile service but this does cost a little more anyway they come highly recommended so give a call if you need your aircon sorting.


 

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Discussion Starter #16
10 August 2009

Spent a bit of time on the Vec yesterday and refitted the under bonnet sound deadening and had a play with the handbrake as it wasn’t balanced properly. As the weather was so nice I also took it to the VXdc Derbyshire club meet.

Before


After


Balancing the handbrake


At the club meet
 

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Discussion Starter #17
29 August 2009

The ‘return to standard’ mods continue as I got hold of a new ABS tailgate badge and decent second hand (thanks Keif) Griffin.


Before



The ST is from ASTRA and the 200 is from two 2.0 badges.


During, even a numpty can’t get it wrong.


All done



The no flash pic was a little blurry so had to use this one as it’s now tucked back into bed.
 

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Discussion Starter #18
22 January 2010

After my ST200 got used for my wedding on the 3rd October it was time to SORN it on the 5th so its back into hibernation over Winter after covering a whopping 393 miles this year. I'm hoping to get my Astra mk2 GTE engine rebuilt over this Winter so will more than likely be using that for shows next year meaning the ST200 won't be coming out to play I'm afraid. I have also got a few jobs to do on the Vec including a lightened flywheel and new clutch but will do these when a few of my other projects are complete.

 

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Discussion Starter #19
22 January 2010

I have finally managed to source a brand spanking new center tailgate badge which are nls from Vauxhall so I'll be getting that fitted at some point.

 

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Discussion Starter #20
24 April 2010

The ST200 is taking a sabbatical this year but it’s not got forgotten as I sold the early LUK clutch I had for it this week as I got the chance to buy a brand new LUK Y26SE clutch for peanuts. My old clutch was sold within 9 minutes of posting the add so pretty good me thinks. The older version clutches are 228mm and the later clutch is 240mm so has a larger face and thus more surface to grip. I also have a billet flywheel which has covered next to no mileage. I’ll get these fitted later this year.

The 240mm clutch kit LUK part number 624 3120 09





Billet flywheel with wear marks from an early 228mm clutch.





Here you can see the extra diameter the new clutch uses



 
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