Spanish Corsa A c20xe

[cicli]

Hi all,

My name is Dani, and I'm coming from Spain. I have posted in some ocassions in the forum, but did not get the chance to introduce myself.

Apart from a c20xe Astra mk3, I own this Nova which I am swapping to be a valver.

Engine is almost standard, apart from lightened flywheel and crankcase pulley and an EDS phase 2 chip. The car will be road legal, and will be my daily auto, so the interior and exterior are fully standard, except the Astra vents on the bonnet. Electrical wiring comes completelly from Astra mk3, so it has fully working bordcomputer or even electrical mirrors.

http://www.clubgsispain.com/attachment.php?attachmentid=39776&stc=1&d=1251031012

http://www.clubgsispain.com/attachment.php?attachmentid=39781&stc=1&d=1251030971

The next step is now to do the exhaust, but I have found what I think is a problem.. My idea is to use an Astra GSI exhaust line and modify it to suit the Nova tunnel. But... the bottom part of the gear lever is just in the middle of the tunnel for the exhaust. And as the car will be standard, I do not want to install the gear lever of an Astra as for the track Novas. Is there enough place for a c20xe pipe? Anybody done?

Regards.

[chimp007_uk]

Welcome...

Good do have member's from the continent.

There's many work arounds with the exhaust system, you can modify a GTE/GSI system to fit the XE manifold.


Different seeing the airbox for a change, looks good!!

Like the 106 in the background, saw alot of them and saxo's racing a silverstone today.

[Rich]

Most common exhaust is to use a upgraded nova exhaust system and to modify the exhaust manifold.

If you buy a performance nova exhaust they are usually the same size bore as the 2 litre exhaust manifold. 2 inch bore i think the manifold is.

The nova looks nice ( do you have rust in spain? lol) what was the model origionally?

[let_nova]

looks good whats the box beside the powercap? on the bulkhead

[let_nova]

cuál es la caja negra al lado del powercap

[craig green]

Airbox is intriguing. Project looks good.

[cicli]

Welcome...

Good do have member's from the continent.

There's many work arounds with the exhaust system, you can modify a GTE/GSI system to fit the XE manifold.


Different seeing the airbox for a change, looks good!!

Like the 106 in the background, saw alot of them and saxo's racing a silverstone today. Thank you.

The idea is to have a 2'' pipe to fit the xe manifold, so thought that a standard system from Astra would do the job.

The 106 belongs to a mate, a 1.3 Rally for rallying.

Most common exhaust is to use a upgraded nova exhaust system and to modify the exhaust manifold.

If you buy a performance nova exhaust they are usually the same size bore as the 2 litre exhaust manifold. 2 inch bore i think the manifold is.

The nova looks nice ( do you have rust in spain? lol) what was the model origionally?
I cannot use a performance exhaust, because to have the car road legal in Spain the boxes need to be legally marked. And the easiest way is to buy a GM pipe. Otherway, I will not be able to get the legalization papers and pass the annual inspections. We cannot do anything in Spain!!! :mad:

If we have what here?

http://www.clubgsispain.com/attachment.php?attachmentid=22348&stc=1&d=1199024587

http://www.clubgsispain.com/attachment.php?attachmentid=22349&stc=1&d=1199024587

http://www.clubgsispain.com/attachment.php?attachmentid=31700&stc=1&d=1219006691

http://www.clubgsispain.com/attachment.php?attachmentid=31712&stc=1&d=1219007143

http://www.clubgsispain.com/attachment.php?attachmentid=31713&stc=1&d=1219007130

http://www.clubgsispain.com/attachment.php?attachmentid=31714&stc=1&d=1219007130

But after many hours I got everything solved. Most of the time I spent on the car has been on the metal, which was not my initial idea. But all these things were covered when I bought it.


looks good whats the box beside the powercap? on the bulkhead

cuál es la caja negra al lado del powercap Hey, nice spanish!!

It is a box from an Astra mk3 which has inside relays and fuses. I took the complete wiring from an Astra, with everything, and just decided that I would look smart.

Airbox is intriguing. Project looks good. Airbox is from a Corsa B, but to allow a better flow it has a homemade foam filter.

Cheers.

[AlexW]

Airbox is from a Corsa B, but to allow a better flow it has a homemade foam filter.

Cheers.

Did you have to cut out all the bottom off it too? I have one fitted on my nova and it now has a lot of it cut to make it fit.

Nice to see somone who speaks good english, Presuming your not using a translater lol

Looks like a nice car, being a GSI too, nice colour aswell! Thats a lot of rust there too, same as british novas i guess, i guess its the humid air and the heavy amounts of rain (When you get it lol)

[cicli]

Did you have to cut out all the bottom off it too? I have one fitted on my nova and it now has a lot of it cut to make it fit.

Nice to see somone who speaks good english, Presuming your not using a translater lol

Looks like a nice car, being a GSI too, nice colour aswell! Thats a lot of rust there too, same as british novas i guess, i guess its the humid air and the heavy amounts of rain (When you get it lol) Yep, the bottom part needs to be cut. It is that, or cutting metal to make a hole like the one in the Corsa B. But I honestly prefer the first option :) In any case, it just fitted like hell!!

http://www.clubgsispain.com/attachment.php?attachmentid=38591&stc=1&d=1246197684

I live in the north of Spain, which is green, cloudy and rainy. Nothing to do with the tourist areas in the south and southeast.

Great to find so much crazy people for Novas in here :d

[let_nova]

pm'd

[16v Nova Kev]

hi dani i used an astra gsi exhaust for my nova xe. it has a bend in it that i used to pass the gear linkage i will try to get pics for you:thumb:

[LEWI007]

GSi XE ftw :thumb:

[cicli]

hi dani i used an astra gsi exhaust for my nova xe. it has a bend in it that i used to pass the gear linkage i will try to get pics for you:thumb:
Would appreciate that a lot!!!

Thanks mate.

[cicli]

I have gone through the Astra mk2 exhaust pipes, which are below in order: 20SEH, 20NE, C20NE, 20XE & C20XE.

http://www.clubgsispain.com/attachment.php?attachmentid=39790&stc=1&d=1251151877

The 20NE line does not have cat/flame extinguiser and seems to be ideal, but the pipe has probably less diameter than the 2'' series of the xe.

Which pipe do you refer to when saying Astra XE?

Best regards.

[dj_wudgey]

welcome matey!! nice to see we have members from all over the world not just britain!!!

[mayhem]

buenos dias lol

didnt the first kadett gsi's have the same gear linkage as a nova? imo a NE system would work, my previous c20xe A corsa had a 1.6 system on it, and that ran fine

[cicli]

buenos dias

didnt the first kadett gsi's have the same gear linkage as a nova? imo a NE system would work, my previous c20xe A corsa had a 1.6 system on it, and that ran fine
It ran fine, but not properly :d

I think will try to find out if the interior console and the Vectra gear lever mod are compatible.

Some other photos of the project:

Place for the third part of the wiring going to the engine bay
http://www.clubgsispain.com/attachment.php?attachmentid=35328&stc=1&d=1234096365
Too much wiring for too few space
http://www.clubgsispain.com/attachment.php?attachmentid=36043&stc=1&d=1236457741
Megasquirt works for future installation of ITB's. It will totally Plug&Play to the Motronic connector.
http://www.clubgsispain.com/attachment.php?attachmentid=36052&stc=1&d=1236551837

http://www.clubgsispain.com/attachment.php?attachmentid=36169&stc=1&d=1237157374

http://www.clubgsispain.com/attachment.php?attachmentid=36170&stc=1&d=1237157374

http://www.clubgsispain.com/attachment.php?attachmentid=36931&stc=1&d=1239387103

http://www.clubgsispain.com/attachment.php?attachmentid=36933&stc=1&d=1239387103
Fuel regulation and measurement
http://www.clubgsispain.com/attachment.php?attachmentid=31732&stc=1&d=1219007948
Lightened door handles (thanks a lot to Olly for the idea ;) )
http://www.clubgsispain.com/attachment.php?attachmentid=31733&stc=1&d=1219008057
MID fully working. Just need to make a signal converter from the digidash signal for speed to the computer in order to get the right speeds and consumption.
http://www.clubgsispain.com/attachment.php?attachmentid=36958&stc=1&d=1239486367
Full reinforcing kit
http://www.clubgsispain.com/attachment.php?attachmentid=31716&stc=1&d=1219007254
Installation of central lock in the boot using a Cavalier motor
http://www.clubgsispain.com/attachment.php?attachmentid=37567&stc=1&d=1241986985

http://www.clubgsispain.com/attachment.php?attachmentid=37573&stc=1&d=1241988485
Regards.

[cicli]

Other images

Handmade Nova electric mirrors
http://www.clubgsispain.com/attachment.php?attachmentid=37911&stc=1&d=1243370376

http://www.clubgsispain.com/attachment.php?attachmentid=37913&stc=1&d=1243370380

http://www.clubgsispain.com/attachment.php?attachmentid=37915&stc=1&d=1243370380
Engine hydraulic damper
http://www.clubgsispain.com/attachment.php?attachmentid=39069&stc=1&d=1248012332
Belts from Rover 114 (I think it is Metro for you)
http://www.clubgsispain.com/attachment.php?attachmentid=39321&stc=1&d=1248987115
Other minor details
http://www.clubgsispain.com/attachment.php?attachmentid=39741&stc=1&d=1250717098

http://www.clubgsispain.com/attachment.php?attachmentid=31706&stc=1&d=1219006864
Regards.

[scott.parker]

Welcome from Spain, your English is better then oms from the UK lol

As for the car, god i thought it was just UK cars that rusted that bad, good on you for not giving up.

Scott

[G-nova]

thats alot of electrics lol how did you make your own electric wing mirrors?

[cicli]

Welcome from Spain, your English is better then oms from the UK lol

As for the car, god i thought it was just UK cars that rusted that bad, good on you for not giving up.

Scott
It is not really usual to have such an amount of rust, even here in the north, but this time happened... :(

thats alot of electrics lol how did you make your own electric wing mirrors?
The internals are from an Astra mk3 GSI and the carcase is the Nova.

Regards.

[Mazz]

Welcome from Spain, your English is better then oms from the UK lol

english fail Scott!

Nova looks good, like the boot central locking, was it easy to do? Just run wires from one of the door motors to the boot?

[cicli]

english fail Scott!

Nova looks good, like the boot central locking, was it easy to do? Just run wires from one of the door motors to the boot?
Yes, you just need to wire in parallel to the boot. Use the motor and the lock from a Cavalier 5 doors, because the 4 doors lock does not fit.

Regards.

[cicli]

Anybody knows the reference of the 22mm master cylinder which was installed in the first Astra mk2 GSI/GTE? I know it is the only direct fitment to get a bigger diameter with the Nova servo, but am not able to allocate it in the EPC :(

My master cylinder died yesterday. I started screwing one of the brake lines missaligned and the thread disappeared. Stupid!!!!

Thanks.

[cicli]

Well, finally I decided to install another original pump.

I have realised that with the 205 width tyres I will need Hulk arms to move the steering while parking, so hacve decided to install a power column.

I know the Corsa B ones are direct fitment, but what about the Corsa C? Is the linkage to the rack and to the steering wheel hub the same? I have seen that these newer ones have a smaller ECU already integrated on the column.

Cheers.

[AlexW]

Corsa C ones have different wheel splines, fine if you want to run a aftermarket wheel, not so good if you want a standard item.

Both B and C will need a mount at least though.

[Edd]

What parts did you use to make the electric mirrors?

[cicli]

What parts did you use to make the electric mirrors?
It is just the carcase of the Nova mirror with the inner mechanism of an Astra mk3.

[7ova]

nice work mate :thumb:
keep it up!

[zeifer33]

A perfect work, men

ya me explicaras como colocar ese ordenador al corsa:d

A cuidarse.

[cicli]

Tryed to give a spark plug cover a carbon aspect. And it seems the 3M Di-Noc vinyl plus a lacquer works worthy...
http://www.clubgsispain.com/attachment.php?attachmentid=41591&stc=1&d=1257803991
Have bought a Pulsar GTiR intake manifold, with its plenum and ITB's :d

Will need to make a hard work trying to weld on the flange of an xe manifold with my TIG welder. There is not too much space to make the work, since everything is packed in a very short distance...:roll:
http://www.clubgsispain.com/attachment.php?attachmentid=41675&stc=1&d=1258154895
And the MS finally started working. I have just updated it to the MSnS Extra firmware to make use of the many features it provides.
http://www.clubgsispain.com/attachment.php?attachmentid=41666&stc=1&d=1258062294

http://www.clubgsispain.com/attachment.php?attachmentid=41667&stc=1&d=1258062296
There is something not clear to me before working on the ITB's. How is the idle managed when installing them? Is the original idle control valve useful no more, or can it be divided into four small hoses and plugged to each body?

I know I can always get rid of the mass airflow meter and use the Alpha-N mode, but I would also like to use the plenum of this intake and keep it for a smoother running. I want to test everything, let's say. In the comparison, is the knowledge lol

Regards.

[cicli]

The car has the full loom coming from an Astra mk3 GSI, so the MID is fully working. At the same time, I am using a LCD dash from a mk2.

Due to this, I have a couple of problemas somebody can probably help me with:
- The speed signal comes from the transducer of the LCD, so the MID is not getting the proper frequence and consequently nor the speed, either the mileage are correct.
- The MID is set for a fuel tank of Astra mk3, so the mileage is not correct since the Nova tank is quite smaller. Is there any way to programm the MID for a smaller tank?

Regards,
Dani.

[cicli]

Well, the car is already road legal, but still progressing on some aspects.

Right now this is the appearance of the bay:
http://www.clubgsispain.com/attachment.php?attachmentid=46543&stc=1&d=1284751184
waiting for the throttle bodies to be ready. And this is the idle with the dBilas 272º cams http://www.youtube.com/watch?v=B239j_-PqXg

They ITB's are progressing, but slower than expected...
http://www.clubgsispain.com/attachment.php?attachmentid=46659&stc=1&d=1285973529

http://www.clubgsispain.com/attachment.php?attachmentid=46661&stc=1&d=1285973529
Unfortunately, the last week the engine decided to create some mahonese on its own, so the opportunity to make some work on the head has arrived :d

http://www.clubgsispain.com/attachment.php?attachmentid=46791&stc=1&d=1286835344

Regards,
Dan.

[bazil]

Good build, that amount of wires would scare the shoite out of me and give me nightmares lol

pity about the head going porous but as you say it's an opertunity to improve.

[nova_niek]

Right now this is the appearance of the bay:
http://www.clubgsispain.com/attachment.php?attachmentid=46543&stc=1&d=1284751184


Mmmm nice! :thumb:

Unfortunately, the last week the engine decided to create some mahonese on its own, so the opportunity to make some work on the head has arrived :d
http://www.clubgsispain.com/attachment.php?attachmentid=46791&stc=1&d=1286835344
Regards,
Dan.
Ouch! Hope it's just the head gasket that's gone and not the head gone porous. Good luck with her. And yes, you're right about the head being off giving you a nice opportunity to "massage" it a little bit. :d

Cheers,
Niek

[Iain]

I like the carbon fibre appearance rocker and plug cover - is it done using flexible carbon fibre sheet?

[tb16v]

Liking the carbon effect! ;) Looks like a porous head tho, very common

[cicli]

I like the carbon fibre appearance rocker and plug cover - is it done using flexible carbon fibre sheet?
Nop, it is real carbon sheet and epoxy to make a skin over the rocker cover. It takes many, many hours, but the result is great :)

[cicli]

Things have progressed slowly since the head/head gasket said goodbye.

I have been working on the head channels and already have the material to make the oil bypass on the outside

http://www.clubgsispain.com/attachment.php?attachmentid=47440&stc=1&d=1289951000

http://www.clubgsispain.com/attachment.php?attachmentid=47442&stc=1&d=1289950996

http://www.clubgsispain.com/attachment.php?attachmentid=47445&stc=1&d=1289950996
First steps of the repair to make the bypass

http://www.clubgsispain.com/attachment.php?attachmentid=47501&stc=1&d=1290120760

http://www.clubgsispain.com/attachment.php?attachmentid=47504&stc=1&d=1290120760
Pulsar throttle bodies adapted. Now I am trying to make a vacuum accumulator to connect the idlle valve, servopump, oil feed...

http://www.clubgsispain.com/attachment.php?attachmentid=47540&stc=1&d=1290303110

http://www.clubgsispain.com/attachment.php?attachmentid=47541&stc=1&d=1290303119
Some pics of the inlet in place

http://www.clubgsispain.com/attachment.php?attachmentid=47425&stc=1&d=1289756953

http://www.clubgsispain.com/attachment.php?attachmentid=47423&stc=1&d=1289756953
And some details of the throttle actuator or position sensor...

http://www.clubgsispain.com/attachment.php?attachmentid=47542&stc=1&d=1290303119

http://www.clubgsispain.com/attachment.php?attachmentid=47544&stc=1&d=1290303119
Regards,
Dan.

[Nobby]

now that has got to be the only thing in the world not already done to a nova well done!

[cicli]

now that has got to be the only thing in the world not already done to a nova well done!Not too sure. Probably everything has already been done to a Nova lol

Well, the throttle bodies are ready, with a vacuum chamber at the bottom to join the idle valve, the cilinders, the fuel pressure regulator...

http://www.clubgsispain.com/attachment.php?attachmentid=47706&stc=1&d=1290982325

http://www.clubgsispain.com/attachment.php?attachmentid=47707&stc=1&d=1290982325

http://www.clubgsispain.com/attachment.php?attachmentid=47708&stc=1&d=1290982325
Regards.

[Nobby]

fuking ace matey!

[NOV4_SPORT]

Hello and welcome, love the work you have done to the nova, loving the skills you have mate.

iain

[scott.parker]

Looking interesting mate, whats the flexi hoses for from the bottom of the TB's? is that a fuel rail?

Scott

[dj_wudgey]

that rocker cover looks well cool matey!!

[cicli]

Looking interesting mate, whats the flexi hoses for from the bottom of the TB's? is that a fuel rail?
No, those are the idle lines. The big connection on the stainless pipe goes to the idle valve.

[cicli]

Well, the engine is already running with the ITB's http://www.youtube.com/watch?v=zGssuciUTLY

The management is the standard Motronic 2.8 EDS Phase 2 chipped. The Megasquirt will be the next step.

The inlet is running with a c20xe AFM inside the pipe of an c25xe one. It seems to run OK, let's see the fuel consumption...

[shed-on-wheels]

really impresed dude with i had the gut5s to chop up itbs and weld them to another manifold ect lol well done matey

[cicli]

The car went yesterday onto the Dyno to check how the things were going on. As I installed a wideband lambda some days ago, we would be able to check the AFR through the whole range of rpm.

At first instance the engine only gave 150bhp, but the AFR was over 14,7 running with 3,6 bars of fuel...
On the second try I moved up the pressure to 3,9bar and it gave 160bhp with values around 14,2 AFR at full power.
On the third try I moved the pressure up to 4,2 bar. This would be the last try because I was worried about having leaks in the fuel lines. The car gave more than 172bhp, but still the lambda values were over 13.5 AFR. It is asking for much more fuel!!!

To get the optimal AFR around 12.8 for full power I will have to use the c20let yellows or something similar. I am impressed that the stock blue injectors are not working as they should with such a small increase of power... At so high pressure they might not be closing properly and the idle went up and the engine goes very rich in the low range or rpm...

I also had problems with the c20xe flow meter into the c25xe pipe, because the car is not idling good, it does not work in some rpm ranges and the end power is low... so it is a very, very big bottle neck in my inlet the stock flow meter I am using these days. I think that the Megasquirt will need to appear earlier than expected to get rid of this **** :cool:

Will upload later some photos and the graph of the final launch on the rollers.

Regards,
Dan.

[cicli]

The photos on the dyno
http://img97.imageshack.us/img97/9696/dsc0057pd.jpg
http://img689.imageshack.us/img689/1904/dsc0058vg.jpg

and the graph with the blue injectors giving the rest :mad:

http://www.clubgsispain.com/attachment.php?attachmentid=48548&stc=1&d=1295745648

Regards,
Dan.

[Nobby]

ace mate i didnt think that you wore coats in spain!?

[Balley]

Very nice :)