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Dannyboi16v · Posted: Mon Oct 06, 2008 4:26 pm Post subject: c20 xe into mk4 astra

this is a rough guide i wrote up for another site, i hope someone will find it usefull

this is a rough guide of how to put a 2.0L redtop engine into an Astra G

tools Needed

Socket set
large socket set
torx set
spanner set
screwdrivers
trolley jack
axle stands
pliers
wire cutters

i'm writing this assuming the 2.0L redtop engine is out of the doner car as there are a few cars that have the same engine

with the engine you will need;

ecu and loom
driveshafts
gearbox
coil discharge pack
waterpipes

with the car on the ground

- disconnect the battery
- disconnect all wiring looms
- disconnect waterpipes
- disconnect the gearshift selector
- the ecu is connected to the passenger side of the block, disconnect the wiring going into it
- disconnect the accelerator cable
- disconnect the clutch line it runs from the gearbox to behind the block!
- blead the fuel lines with the bleed nipple on the fuel rail and take off the fuel lines going into the fuel rail
- disconnect the vacuum hoses and the hose going to the brake servo
- if you have an air box remove that too

jack the car up and rest the car on axle stands safely

now the cars in the air

- take off the 2 front wheels
- remove the split pin in the hubnut and undo the hubnut what holds the driveshaft in place ( you will need someone to press the foot on the brake for your to do this)
- disconnect the brake lines
- undo the 2 bolts the hold the brakes to the suspension both side
- then you can remove the drive shafts from the hubs
- pull the driveshafts out, at the same time place an oil catch tray underneath them as oil will spill out
- now undo all engine mounts they are located on the drivers wing, front of gearbox, and rear mount
- with all the mounts out you are read to lift the engine out!

this process took me around an hour going quick! time may vary

no you have the engine out it's time to get the 2.0L ready to drop in, sounds easy? yeah right! smile

i left the subframe in the first time i put a C-series engine into the astra because you need to rest the engine on it to line upp your new mounts you have to WELD!

Fitting new engine into your Astra

- hook the engine onto the engine crane, i did this with the gearbox attached which is alot easier than doing it after
- lower the engine and box into the bay
- line up the rear engine mount and connect it up ( you need to connect the mount from your old box to the new one)
- now with the engine still hooked up to the crane you have to get it perfectly straight for the the new mounts, i used a special digital tool for this
- now big companies such as lmf ect sell conversion kit mounts but can cost upto £700, i made my own up and cost me absolutely nothing!
- the drivers side mounts bolts onto the front of the block with a rubber at the end. with the engine straight i placed my home made mount on the body and welded it on
- the gearbox mount bolts to the front of the box, again with the engine lined up straight you weld your conversion plate to the body and bolt the mount to that.
- now your engine is sat in the bay fully mounted up you can remove the crane
- then put the driveshafts, hubs, wheels, gear shift selector back together ect

now its time for the small fiddly bits and wiring!

with the car back on the ground

-connect all water hoses up, now remember that the pipe coming from the header tank goes the back of the block into the waterway NOT the side of the block, then run a hose from the side of the block to the heater and the other heater pipe runs to the back of the block also. then connect all you radiator hoses up. there will be a hose you don't need.. this is located to the left of the throttle body at the back of the block.. bung that up with a bolt or bleed valve ect.
- you will need and ecotec adapter plate because you haven't got a hope in hell putting the original SFI box onto the throttle body
-now for the wiring you need a Haynes manual for your car and also the doner car that the engine came out of. to check wiring diagrams for ignitions lives ect
- don't forget to plug the coil discharge pack into the loom or you wont get a spark.

thats just about it for getting it in and ready to run.. it's up to you where you mount the ecu ect i fed mine into the dash but that involved a hole cutter

now all you need to do is line the gears up which is also explained in the Haynes manual and bleed the brake, clutch lines ect

check everything over as you've just done too much work for it to go wrong!!

this is just a rough guide and i wont be held responsible for any damage to your car, this is the way i done it and it works fine

flatout · Posted: Mon Oct 06, 2008 6:18 pm Post subject:

ideally before the new engine goes in, a hole needs drilling big enough for the loom to pass through on the drivers side so you can mount the ecu behind the clocks.

also the return fuel line needs running directly to the tank as the fuel return as standard is no good on injected models.

also the fan will need to go on a seperate switch because once the let ecu is wired in it can't control the fan.

mk4's have a fuel pressure regulator in the tank this needs removing as the xe/let's have there own on the fuel rail.

anything else i can remember i'll add later Thumbs Up

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Rich_j_williams built chips engine ;)

Dannyboi16v · Posted: Mon Oct 06, 2008 6:23 pm Post subject:

flatout · Posted: Mon Oct 06, 2008 10:04 pm Post subject:

GarySRi · Posted: Mon Oct 06, 2008 10:09 pm Post subject:

the mount is what interests me the rest is simple enough

Dannyboi16v · Posted: Mon Oct 06, 2008 10:15 pm Post subject:

GarySRi · Posted: Mon Oct 06, 2008 10:28 pm Post subject:

The fabricated one

Dannyboi16v · Posted: Mon Oct 06, 2008 10:36 pm Post subject:

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does need a 600bhp wheelspin machine!! 160bhp just isnt enough Sad

flatout · Posted: Tue Oct 07, 2008 10:34 am Post subject:

if your using a f28 the front mount needs to be fab'd or bought for that too, chris astley sells em tho Thumbs Up

_________________
Rich_j_williams built chips engine ;)

Dannyboi16v · Posted: Tue Oct 07, 2008 11:23 am Post subject:

oh ok, the guide is based on c20xe with f20 fella
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does need a 600bhp wheelspin machine!! 160bhp just isnt enough Sad

iPod · Posted: Sun Oct 12, 2008 8:34 am Post subject:

Has anyone got any pics of the conversion done??? And some pics of the the brackes that need to be fabricated....

mark.c.84 · vauxsport.com Joined: 19 Mar 2007 Posts: 6

Hi Mate you got any pics/spec of the mounts you made for the engine and box
cheers in advance Mark

flatout · Posted: Sun May 03, 2009 11:52 am Post subject:

did you get the pics you wanted? ive got some floating around i could pm you if ya wanted Thumbs Up

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Rich_j_williams built chips engine ;)

GAZ`D · Posted: Sun Jun 14, 2009 4:41 pm Post subject:

i used a mk4 sri gearbox on mine and the gearbox mounts from the same so straight bolt in job(no modification at all) just the engine mount as above also my fan works fine just used the sender fron the original diesel engine that was in the car it screws straight into the hole where the xe temp switch is Thumbs Up

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i`m not smart enough to know i`m stupid

GAZ`D · Posted: Sun Jun 14, 2009 5:04 pm Post subject:

different sender from diesel

made my own mount for the engine too

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i`m not smart enough to know i`m stupid

stee · Posted: Mon Jan 04, 2010 10:49 pm Post subject:

Were abouts did people cut there hole in the bulk head any pics and also mine has had the standard z20let loom and ecu taken about but im going to use a c20let not a xe