Project 'Keep the mrs happy'

[joff-turbo-nova]

After a few months digging and searching around for a decent run around for the wife I have found this :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/meriva2.jpg

Its on a cat c salvage marked but just needs a whole door and we're away.

Mine was the only bid so I think I have done OK - can secure a whole door from a local breakers for about £140 and with the paint costs onto of about £60 and the VIC test I think I have a nice bargain!

Auction was here :-

Meriva ebay auction (http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=390121237026&ssPageName=STRK:MEWAX:IT)

Aparently when the cat c was allocated no keys were available , but since then they have now been recovered so its just the door that needs sorting.

They do VIC tests 8 miles away which is also handy!

Should be on the road in a couple of weeks - but may wait until January so I get a full months tax on it.

Joff

[John]

loadsa room for a v6 in there! Link for auction not working dude.

[Spudly]

Fixed now, not too sure what he did there but ive sorted it lol

[nova danny1]

bargain mate,vxr kit?

[Spudly]

bargain mate,vxr kit?


We all know Joff wont be able to resist playing with it a little lol

[fearless]

Watched the end of the auction Joff and I assumed it was you putting the last minute bid in - nice easy project for you

[joff-turbo-nova]

Watched the end of the auction Joff and I assumed it was you putting the last minute bid in - nice easy project for you

Yep that was me - I normally only put bids in with about 20 seconds to go!

Joff

[joff-turbo-nova]

We all know Joff wont be able to resist playing with it a little lol

I've already started and I haven't even picked it up yet - just bought one of these to make the back end a bit more modern :-

Meriva chrome strip (http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=380182113803&ssPageName=STRK:MEWAX:IT)

http://i.ebayimg.com/22/!Bbn8h)wB2k~$(KGrHqQOKiIEq49g4CNKBKw40I26Gg~~_12.J PG

Joff :thumb: :thumb:

[Ben]

Get thevic booked asap as they can take a month to get you in, not sure about up by you but with our local center if you go in the center to book it can get one next day, if you send the paperwork off to the dvla then can take 6-8 weeks for an appt.

Oh yeah its cash or cheque only if you go in person.

[Markd89]

got a vic place in beverley, if you go in ask for mike he will sort you out :)

[Pistol Pete]

Bit of a bargain there. Last minute.com bidding FTW!!!

[Mike]

Top bargain. My dad paid £8k for his 04 reg one in August 04, so yeah, even for a Cat C you got it for a good price IMO.

Nice to drive aswell an the boots pretty big, huge when you flip the rear seats down!!

[Ben]

My dad paid £8k for his 04 reg one in August 04, !

So it was nigh on brand new?

[Mike]

So it was nigh on brand new?

Basically yes, had about 18k on it.

[Ben]

18k in a few months thats a lot of miles!

[joff-turbo-nova]

Bit of an update, went to collect the new Meriva yesterday (Saturday). Hired a trailer from a local chap for £50 for the day.

Arrived in Peterborough at about 9:30 (been on the road since 6am) .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0199.jpg

Checked it all over and double checked the VIN numbers all matched up. Paid my money and got the new door put on with some brand new door pins I got from Vauxhall last week ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0200.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0201.jpg

After a rather uneventful drive home at 60 mph I finnally arrived back at about 1pm and started unloading - the bed of the trailer tips which makes loading and unloading quite easy!

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0202.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0203.jpg

Had a good look round the vehicle and there's a few areas that need attention .

There's a mark on the front bumper :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0205.jpg

The rear neaside arch has a scuff :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0204.jpg

And there are a couple of parking dints along with the new door that need sorting.

Had a good root round in the car to see what else was in it . This is a bit bizzare ..... under the rubber mat in the front console I found $15 US dollars (about £12 UKP) - billy bonus !!!

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0208.jpg

The interior looks like its been used by farmers as its really grubby ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0207.jpg

but nothing that my steam cleaner and wet vax can't sort out - not too sure on the colour (light grey) - may try and get a black interior at some point.

Its all now secure with all the locks and electrics working on the new door - even got both sets of keys with it !!

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0206.jpg

Its booked into the spray shop next Saturday and they said it should be back by the end of the week.

Enjoy

Joff

[Ben]

The damage was light enough if you got the door straight on, good buy.

[joff-turbo-nova]

The damage was light enough if you got the door straight on, good buy.

There was no damage around the door - it had been stolen for spares - they started stripping the car and got as far as removing the hinge pins and wiring plug and then the door and thats as far as they got.

The new door just fitted straight on and plugged in no problem.

I'm happy so far with this mini project!

Joff

[L14MNP]

Nice purchase mate. I detest vehicles like this TBH, but for the wife it's ideal. I cannot believe Vauxhall are still using door pins though! They also look like Vectra seat belt buckles? lol

[Mike]

As said Joff, there decent cars, both the ones my dad had were really nice to drive.

Irmscher do some right nice parts for them to...

[Ben]

I cannot believe Vauxhall are still using door pins though!

Quite right when the rest of the world discovered bolt on hinges vauxhall were building vxr engines lol

[dave watson]

Quite right when the rest of the world discovered bolt on hinges vauxhall were building vxr engines lol

haha well said who needs a hinge when you can have a vxr engine have some rep :thumb:

[Zeus]

Heres a virtual I did about 4 years ago:
http://i3.photobucket.com/albums/y79/GroupB/Virtually%20Modified/meriva.jpg

[nova_sri_kid]

that looks mint

[L14MNP]

Quite right when the rest of the world discovered bolt on hinges vauxhall were building vxr engines lol

Oh really? VXR engines are still fairly new. The modern car world has been bolting on doors for decades. lol

Poor old VX. Always behind the times. lol

[joff-turbo-nova]

The front bumper had a few scuffs and scrapes so I have rubbed it down and filled where appropriate ready for the bodyshop ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0229.jpg

Also pulled the calipers apart , cleaned them up and hammerited them before putting back together with new discs and calipers ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0230.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0231.jpg

Its now at the spray shop for the bits to be sprayed and then MOT'ed (hopefully will be OK).

There is some knocking noises coming from the front when you go over smallish bumps - I suspect its either the roll bar link bars or the bottom arms - either way its not a problem as I have some new ones of both coming from Autovaux next week.

I have a some rear discs and pads coming as well along with a timing belt kit, water pump and new gear linkage.

Cheers

Joff

[Pistol Pete]

lol nice tidy workspace you got there!!!

[joff-turbo-nova]

lol nice tidy workspace you got there!!!

Ay it gets a bit like that when I'm busy - will have a tidy up next week !

Forgot to mention that the pads I removed were rather low on pad material, let the pics speak for themselves :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0237.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0238.jpg

Joff

[saloonwoody]

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0199.jpg

good ol dk salvage :)

[joff-turbo-nova]

Been busy since Christmas on the major service for the Meriva.

Got on with the cam belt change - whilst I was there I changed the idlers , tensioner and water pump ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0303.jpg

It was quite tight in places but not as bad as a XE/LET in a nova lol .

Next was hammeriting the engine subframe which was a bit cruddy in places ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0304.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0301.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0305.jpg


Also changed the front bottom arms and rollbar link rods as well.

Next up was a new gear linkage .... which was a ball of a job ..... but I have removed the plastic parts which aparently wear out quickly on these and Corsa C's which give gear selection problems......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0306.jpg

After changing the air filter, oil filter and pollen filter it was time to hammerite the floor pan .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0310.jpg

Next up was the back end which again needed some TLC ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0314.jpg

The rear discs needed changing .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0311.jpg

.... and the rear calipers needed a service ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0312.jpg

[joff-turbo-nova]

So I stripped down the calipers and painted them up ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0315.jpg

... and painted the back plates as well .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0316.jpg

and then reassembled everything back together .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0317.jpg

Just need to hammerite and waxoyl the back end and I'm ready to put it on the road Monday morning.

Joff

[puss puss]

I thought it was just a fix and use thing?

Looks more like a project now to me lol nice find buddy :)

[joff-turbo-nova]

I thought it was just a fix and use thing?

Looks more like a project now to me lol nice find buddy :)

The major service included new brakes all round .

What I didn't know when I bought it was the general condition underneath. The bodyshell is fine, its the bits hanging off it that have rusted a bit - looks like it has been sat on the front in Bournemouth for a couple of years.

A good coat of hammerite and lots of waxoyl and underseal will sort it out.

Previous owner lived in Cambridge so it wasn't whilst it was there!

Joff

[joff-turbo-nova]

Finished off the waxoyling - even took off the back bumper and did a "proper job" -


http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0320.jpg
Then finished off with a nice coat of black underseal to keep out the elements!


http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0321.jpg

Looking at the forecast I think I may delay putting this on the road until 1st Feb to get some of the cr@ppy weather out of the way !

Now sorting all the paintwork out - the roof has moss growing on it so its time for the cutting polish and the Megs I think!

Joff

[Spudly]

Looking good there Joff, id delay it a bit if you still have the lil corsa on the road, less chance of any ice related dings or knocks if you get me lol


So wheres the loon/sleeper/tailor/mobilehome whilst the meriva is in the nest then?

[joff-turbo-nova]

Looking good there Joff, id delay it a bit if you still have the lil corsa on the road, less chance of any ice related dings or knocks if you get me lol


So wheres the loon/sleeper/tailor/mobilehome whilst the meriva is in the nest then?

Looking rather white sat on the drive with a cover on it !!!

Also picked up this little bargain tonight - an Irmscher rear skirt (attached to another bumper) along with a rear repair panel and bumper bar - all for £30 !!! The skirt alone is normally about £130 !!

Will sell on the bumper , bumper bar and back panel in due course.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0324.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0325.jpg

Joff

[joff-turbo-nova]

Got a bit busy with the newly aquired bumper - removed the lower skirt which is actually made by Zender and not Irmscher as I orignally thought, never the less its still just the one I want . So rubbed it down with wet and dry ready for the spray shop.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0335.jpg

Also got hold of a Lester Rear Spoiler as the top of the tailgate looked a bit bland. Didn't fancy paying £205 for an Irmscher one at my local dealer, as found on the VXR version, so this comes in a close second and a lot less than half the price of the Irmscher one ......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0336.jpg

This is what it looks like attached (not a particularly good picture) .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Lesterspoiler.jpg

Both were dropped off at the body shop this morning and will be ready next week.

Also collected from the local dealer a new battery tray as the current one is very rusty - to my suprise they are now plastic - a much better idea ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0337.jpg


Also collected a new interior from an 2008 model which is miles better than the current one. I got all 5 seats, carpets and 4 door cards and a chrome handle all which match ! Its a black cloth with little dots on it ......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0339.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0340.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0341.jpg

Much better than the current seats which are VERY grandad .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0342.jpg

The new seats although look clean have been sat in a salvage yard for about 3 weeks so could do with a light clean - however they got soaked today removing them as it was chucking it down so they are all sat in my dining room next to the radiator drying out - and bonus - the wife loves them !!

Joff

[Mike]

Joff, you need to stop posting in this thread.......i made an epic mistake of showing my old man your Meriva, an now your giving him sheetloads of ideas for his Meriva.

Only problem is, hes not car literate, an has now passed the job onto me :( damn you lol lol

[Mazz]

That black interior is sooo much better than the grey

btw, fancy measuring the front disks to help here (http://www.pngclub.com/forum/showthread.php?t=138221&page=4)

[joff-turbo-nova]

Got busy with the new door cards tonight -done the rear nearside -took the old door card off - waxoyled the inside of the door fiddled with the speakers and put the new door card on - looking much better ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0343.jpg

I've half done the offside rear. I noticed that the rear doors on most of the Vauxhall's I've worked on seem to have spaces for two way speakers (mid and tweeters) but only have the mid speaker installed. Well I've now addressed this issue with the Meriva - just needed to splice a new wire onto the existing harness (the black stuff is the waxoyl) ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0344.jpg

Then get the speaker grille which lives next to the door handle ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0345.jpg

And fit the tweeter in place - these were out of a corsa so were a bit bigger than the fixings on the grille - nothing a set of side cutters and a hot glue gun couldn't sort out....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0346.jpg

The rear sounds heaps better now that you can hear the low/mid AND high notes ! Strange to put the speaker hole in the design and then never use them - I take it somewhere along the line there has been a speaker upgrade kit offered by Vauxhall ??

Next up is the front doors - dead easy - no windy down handles to get in the way with their stupidly fiddly clips which won't come out lol

Joff

[Mike]

Top work Joff!

Re the tweeters, Corsa B's & C's are the same, all the clips & fittings are there, but theres no speaker installed just the wiring.

[joff-turbo-nova]

Evening all,

A bit more mincing done this weekend in readiness for going on the road for the first of February ......

Got the new spoiler and lower skirt picked up Friday ......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0352.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0353.jpg


So it was on with the new spoiler with the aid of some sikaflex .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0357.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0356.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0360.jpg


And some overnight clamping with the sikaflex sorted the lower spoiler too ...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0389.jpg

It was out with the old (which actually took ages because of the flexible seating mechanism on the back seats - there are 12 T40 torx bolts that hold the back seats in) .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0361.jpg

Also took a while because a couple of the bolts rounded off (torx plus thread lock = problems) so I had to get busy with the mig welder and a M8 nut !

Next up was the carpets (lovely light grey colour) ......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0363.jpg

It was then in with the new - a black carpet .......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0366.jpg

And then back in with the new seats (which took nearly as long as getting the old ones out - Torx I love them !) ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0367.jpg

Must say that they look miles better than the old ones especially with the darker carpet . NB also found a 50p under the front seat along with some paracetamol :confused:

Front seats are on the cards in the next couple of nights !

Enjoy

Joff

[Ben]

That spolier looks different shade!

Hats off to your work ethic Joff, wish i had a tenth of your enthusiasm!

[Plug]

the darker carpet looks loads better IMO

[joff-turbo-nova]

That spolier looks different shade!

Hats off to your work ethic Joff, wish i had a tenth of your enthusiasm!

I thought that and went to double check - in real life they look the same - I think it must be the flash reflecting off the metalic paint a different way to the existing paintwork.

The rear skirt has been painted with the same paint and looks OK in the pics - its just how the lights been reflected.

Cheers for the comments - my back doesn't feel very "enthusiastic" at the moment !

Joff

[Mike]

Looking loads better nwo that it mate.

[L14MNP]

Did you rob that spoiler from a GTi-R? It's huge lol!

Interior is a massive improvement and the 'aero packgae' tidies the back up nicely.

[joff-turbo-nova]

Quick update....

Got the front seats fitted (even robbed the underseat storage tray from the old passenger seat!) .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0003-1.jpg

Also cleaned up the dash....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0004-1.jpg

And then treated it to a nice seat of genuine Vauxhall mats .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0005-1.jpg

Also picked up a couple of bargains off the bay this week . A set of Irmscher side skirts which normally retail at something stupid like £400 .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/merivaskirts1.jpg

And a front bumper lower spoiler (again go for something like £300 from the dealers)......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/merivaspoiler1.jpg

Both from the same seller, brand new, unfitted and with fitting kits - for £90 for the lot ! Bargain :thumb: :thumb:

Will need to drop them off at the spray shop sometime. Just need to change the thermostat and the battery tray and we're ready for lift off on Monday being the 1st of the month.

Also been quoted £299 for a new stainless exhaust system from the local Longlife franchsie in Doncaster - anyone had any experience on Longlife stuff?

Joff

[Ben]

Our local longlife are decent quality and dont know of anyone having issues, all down to what spec you choose but the materials and workmanship cant be knocked.

[mk1nova]

ive had a longlife exhaust fitted to my astra sri, just make sure they dont do it too loud my neighbours are just getting used to it 4 months later. Good quality took 2 hours and fitted de-cat free (which i supplied).

[Kev Turbo]

Stainless steel exhauts on family people carrier is not a good look!


Credit to the rest of the work though!

[Ben]

ive had a longlife exhaust fitted to my astra sri, just make sure they dont do it too loud my neighbours are just getting used to it 4 months later. Good quality took 2 hours and fitted de-cat free (which i supplied).

lol thats why i put down to your spec my 206 gti had a longlife fitted by previous owner and was insanely loud.

[novacabrio]

Stick with the current theme and track down an irmscher jobbie, would finish the car nice

[joff-turbo-nova]

Stick with the current theme and track down an irmscher jobbie, would finish the car nice



Stainless steel exhauts on family people carrier is not a good look!


Credit to the rest of the work though!

I was thinking about the Irmscher exhaust but its only a back box and retails at a ridiculous price of £500 !! See here - Irmscher exhaust (http://cgi.ebay.co.uk/NEW-IRMSCHER-Vauxhall-Meriva-Rear-Twin-Tailbox-Silencer_W0QQitemZ400083103047QQcmdZViewItemQQptZU K_CarsParts_Vehicles_CarParts_SM?hash=item5d26cfad 47)

However it does look nice (but not £500 nice) .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Merivaexhaust.jpg

There is very little off the shelf stuff exhaust wise for the Meriva - the only other exhaust I could find was from LMF - LMF exhaust (http://www.lmfvauxhall.co.uk/store/home.php?cat=1931) - but again pricey at £272 JUST for the backbox.

I will try and get a bespoke one made which is as quiet as the OE stuff but has two small square-ish tailpipes I think.

Joff

[joff-turbo-nova]

More work today ....

Got on with changing the thermostat - glad I did as the aluminium was disintergrating inside the top hose......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0008-2.jpg

On with the new one without any problems .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0009-1.jpg

Whipped the old battery out which revealed a rather rusty battery tray....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0010-1.jpg

Out with the old and in with the new - a non rusting plastic battery tray....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0011.jpg

Also got a nice 60 ah battery from Vauxhall as well....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0012.jpg

I thought the rear clusters looked a bit bright so got the masking tape out and the tinting spray .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0007-2.jpg

Before ......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Merivaoriginal.jpg

After ......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0013.jpg

Much better !

Just needs a polish tommorrow and its ready to go!

Joff

[joff-turbo-nova]

Did a similar thing with the clusters on the wife's corsa as well ...

Before...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/corsaoriginal.jpg

After....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0023.jpg

Enjoy

Joff

[joff-turbo-nova]

Did a megs stage 2 and 3 this morning and got it out for a mini photoshoot outside the house.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0025-2.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0024-4.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0015-2.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0017.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0020-2.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0018.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0019.jpg

Ready for the road tomorrow !

Joff

[S1M0N]

Good work there, lets hope she likes it! Lol

[vaughanmc]

Looks nice at the rear - Will be nice to see it complete :)

[Mike]

Looking fab mate :)

Some minor debadging might be a good idea i think? Or irmscher style front grill?

[NOV4_SPORT]

Looking good joff mate.

iain

[joff-turbo-nova]

Looking fab mate :)

... irmscher style front grill?

I was thinking about this today, however as usual the Irmscher stuff new is VERY expensive - about £150 delivered for a grille....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/merivairmschergrille-1.jpg

Rossiters do a Steinmetz grille as well for £160 inc P&P -

http://i2.photobucket.com/albums/y15/joff-turbo-nova/steinmetzgrille.jpg

However FK Automotive (over in Germany - same people that do coilover kits) seem to do a very similar one to the above options for £80 ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/fkgille.jpg

It's still a lot of money for a bit of plastic !

Will get the skirts and lower front spoiler on and see how it looks before I make any further decisions!

Joff

[Ben]

buy the clone and a steinmetz badge and no one would notice.

Would set the front of the car off though.

[vaughanmc]

Paint the V grill Matt Black ?

[joff-turbo-nova]

Paint the V grill Matt Black ?

I was thinking colour coded like the VXR's but the silver is too much like the chrome version and won't really look that different TBH !

Decisions ...... decisions .....

[vaughanmc]

Try it Matt Black 1st before spending mega bucks on another grill :)

Southie!!! Photoshop lol

[joff-turbo-nova]

These two packages arrived today.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0027-1.jpg

Inside the box was the nice brand spanky new lower front spoiler ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0034-1.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0035-2.jpg


and in the bubblewrap was the two side skirts .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0036-2.jpg

All confirmed Irmscher stuff with the instructions and fitting kit included :thumb: :thumb: .

Will be dropping them off at the sprayshop later this week !

Joff

[joff-turbo-nova]

Got the parts back from the spray shop last week.

So I removed the front bumper and bonded on the lower spoiler .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0099-1.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0100-1.jpg

Then let it set and got the bumper back onto the Meriva .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0101.jpg

Also decided last week to go with the FK Automotive grille and I had a spare Irmscher grille badge so that got wacked on - looks quite authentic now !

http://i2.photobucket.com/albums/y15/joff-turbo-nova/PICT0102.jpg

Quite happy with the front and rear ends now - just need to get the side skirts on when the weather is a little drier !!

Joff

[Mike]

Top work Joff, proper looking the part now!

[Pistol Pete]

Some nice touches have been done. Top work.

[nova_niek]

Surely the missus doesn't mind you upping the spec of her daily? Nice work! :thumb:

[novalicous]

any updates joff?

[joff-turbo-nova]

any updates joff?

Nope ... got the side skirts to put on but have been waiting for better weather - will probably get round to it over Easter when I have some time off work.

Joff

[xe Dan]

im thinking de badging it a bit would look good get rid of the design badges off the doors and vauxhall and meriva of the boot and will look spot on

[Vlietje]

Joff, if you still want that Irmscher backbox, check Ebay.de found one for you for around € 350,00

Cheers,

Jeffrey

[Pete]

Joff sorry for going off topic, did you see the latest watchdog episode? It had the meriva's featured on there about how the power steering goes on them as your driving.
Does yours have the same problem or not?

[Mike]

^Its never happend on either of my dads Meriva's?

[Plug]

just cause it was on watchdog doesnt mean its a major problem, i reckon there is no more than 50-100 affected in the 1000's sold

[Pete]

nah im not saying it's a major problem, where in my post did i say that?

im just saying that it can be a commen problem on some meriva's

[Spudly]

Im pretty sure he knows about that one as iirc he has a spare epas column in the garage just in case lol

[Mike]

EPAS coloumns are bollox an are renonwed for failing anyway.

Not that it matters as you can still steer with it broke anyway :thumb:

[craig green]

I missed this, thats a cool looking Meriva right there.

[joff-turbo-nova]

Joff sorry for going off topic, did you see the latest watchdog episode? It had the meriva's featured on there about how the power steering goes on them as your driving.
Does yours have the same problem or not?

I read up on the common problems on Meriva's before I bought this one.

Common faults seem to be mainly engine related with the Z18XE engine namely the airflow meter, throttle body, coil packs and ECU (which is sat right on the side of the inlet manifold.


I have spare ones in the garage along with the EPAS column just in case.

There does seem to be an issue with the EPAS on some of the cars but I don't think its as common as its made out to be.

Joff

[joff-turbo-nova]

Right more updates....

Due to an ever increasing oil consumption problem it has come to the point where the engine needs replacing with a new one, so...

I sourced a replacement 1.8 16v from a contact in Nottingham and picked it up a couple of months ago. I should of started work on the engine in mid July however due to a reoccuring back problem, I have only now been able to start stripping the engine.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_9197.jpg



http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18xe001-1.jpg

First job was to strip all the cambelt pulleys and associated gubbins off the side of the engine...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18xe002.jpg

Then it was off with the cylinder head ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18xe003.jpg

The bores seem to be in good condition, I will give them a light hone before the pistons with the new rings go back in. Seemed a fair bit of carbon on the piston crowns which will get cleaned up ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18xe004.jpg

Next job was to remove the pistons ...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18xe005.jpg

Had a look at the shells, seemed to be in good order with little wear, they will be replaced anyway as a matter of good practice...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18xe006.jpg

Got two pistons out before it was time for tea, will remove the other two and the crank shortly.

Plan is to hone the bores, and clean up the block. Rebuild the bottom end with new bearings and oil pump. I'm going to strip the head, clean the inlet and exhaust ports up, remove and clean all the valves up and reseat them in the head and replace all the seals.

I'm cleaning out the lifters rather than replacing them, as at £16 each from Vauxhall I could spend my money better on other things!

Cheers

Joff

[Spudly]

Looking like its a good one even though youre replacing everything lol


Hows Paula finding the disastra then :d

[joff-turbo-nova]

Looking like its a good one even though youre replacing everything lol


Hows Paula finding the disastra then :d

She's not happy - says it smells !!! Patrick calls it the silver shed !

It's my daily from Monday as she's using my Meriva until her's is back on the road ! She's moaning about the fact that the VXR leather seats are "uncomfortable" . She's just got a big bum !

Joff

[Spudly]

Lmfao, i hope for your sake she has forgotten her login details and doesnt end up reading that, or you will be sleeping in the silver shed lol


Theres nothing wrong with the disastra anyways, i really like mine, and its just turned 200,000 on the clock last weekend :eek:




http://i8.photobucket.com/albums/a36/spudly01/55D4742A-837D-48D4-A1BF-38E0B5A5664E-411-0000004D38F6CA6A.jpg




And still sweet as a nut :d

[joff-turbo-nova]

Hey Spud! I may have forgotten my log in but when Joff leaves his account open and I "just happen" to read it, I think I have the right to reply!?!

Oy husband!!! Not happy with the reference to the size of my backside :cry: Cut it out with the insults! :p

It was a shed, is a shed and always will be a shed. lol That is the truth.

BTW your meriva is so slooooow compared to mine. It accelerates like a donkey and corners like a cardboard box. How long til my car is fixed??? :d

[Mike]

BTW your meriva is so slooooow compared to mine. It accelerates like a donkey and corners like a cardboard box. How long til my car is fixed??? :d

Ha awesome lol

[MK999]

Watch out for the thrusts on the main bearings when you pull the crank out Joff, both of mine have eaten the bearing there, and one had eaten about 1.5mm out of the crank.

[Spudly]

Hey Spud! I may have forgotten my log in but when Joff leaves his account open and I "just happen" to read it, I think I have the right to reply!?!

Oy husband!!! Not happy with the reference to the size of my backside :cry: Cut it out with the insults! :p

It was a shed, is a shed and always will be a shed. lol That is the truth.

BTW your meriva is so slooooow compared to mine. It accelerates like a donkey and corners like a cardboard box. How long til my car is fixed??? :d




LMFAO, BUSTED Joff, oopsie lol

[joff-turbo-nova]

Watch out for the thrusts on the main bearings when you pull the crank out Joff, both of mine have eaten the bearing there, and one had eaten about 1.5mm out of the crank.

Will look carefully when the caps come off - cheers :thumb::thumb:

[Vlietje]

Hey Spud! I may have forgotten my log in but when Joff leaves his account open and I "just happen" to read it, I think I have the right to reply!?!

Oy husband!!! Not happy with the reference to the size of my backside :cry: Cut it out with the insults! :p

It was a shed, is a shed and always will be a shed. lol That is the truth.

BTW your meriva is so slooooow compared to mine. It accelerates like a donkey and corners like a cardboard box. How long til my car is fixed??? :d

Hahahahahahahaha... +1 for Paula! :thumb::thumb:

[joff-turbo-nova]

Watch out for the thrusts on the main bearings when you pull the crank out Joff, both of mine have eaten the bearing there, and one had eaten about 1.5mm out of the crank.

Right , pulled the last two pistons out without any issues, then proceeded with the removal of the crank.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE010.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE011.jpg

All the shells seem in good condition with minimal wear on the thrust bearing which sits under cap number 3 right in the middle of the engine ......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE013.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE014.jpg

No major issues with the crank either....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE012.jpg

I'm taking the block up to my dad's tomorrow to use his honing tool to deglaze the bores and let him cast his +45 years engineering experience over the block , pistons and crank just in case I have missed anything.

Oh and the Z20LET is waiting in the corner ready to jump into my Meriva as soon as this engine is installed and working !

Joff

[MK999]

Pics aren't working but glad your thrust faces are all good :)

[joff-turbo-nova]

Pics aren't working but glad your thrust faces are all good :)

Photobucket seems to be having an eppy at the moment - its affecting most of my pics that I have hosted - just noticed the thrust bearing pic has just come up!

Joff

[MK999]

Might just be the clean section but it looks like there might be a little wear on the thrust face of the crank? as long as there's no lip you can feel though, just double check the end float when it's all back together.

[novadave24]

hi joff what spary do you use for the lights ? cheers dave

[joff-turbo-nova]

Got the block honed out nicely on Wednesday and then got it back home Thursday and put back on the stand with the engine hoist (very handy item to have!).

Next job was to clean down the block on both sides :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE019.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE020.jpg


And then give the block it's first coat of engine enamel paint :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE018.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE021.jpg


Tomorrow the block will get another coat of paint and whilst that's drying I hope to start stripping the head and getting the valves out . May give the ports a bit of a smooth with the die grinder whilst its bare as well !

Joff

[joff-turbo-nova]

Update....

A bit more work today, got the crank cleaned up and put back in with new bearings and then got busy cleaning no4 piston up.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE028.jpg

Got the new rings on and got the compression tool out and tapped it in ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE027.jpg

Just need to do the other 3 in the morning . Its very theraputic stripping down pistons , cleaning out all the nooks and crannies and then rebuilding them. Once the pistons are in , its on with the oil pump and pick up pipe and then the sumps going on.

Joff

[joff-turbo-nova]

Cracked on with the engine work today....

Got all 4 pistons cleaned up and new rings and shells installed and put back into the block...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE035.jpg

New GM oil pump was added as well ...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE034.jpg

Cleaned up the pickup pipe as it was rather cruddy and reinstalled with an new o ring....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE033.jpg

Torqued everything down and then put the sump on with some sealant as these engines don't have a sump gasket....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE036.jpg

Next up was starting on the cylinder head , all 16 valves are rather caked with carbon...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE037.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE038.jpg

This was an inlet valve before.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE039.jpg

And this is after cleaning .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE040.jpg

Also thought it would be rude not to get the dremmel out and polish out the ports as they seem to have a very rough casing on the inside, I have left it roughish as I understand these engines work better with the inlet rough, will give the exhaust ports a good going over ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE041.jpg

Need to finish off the polishing with a longer sanding bit.

Enjoy!

Joff

[Spudly]

Seriously Joff, you find yourself needing an extra project, ill happily let you rebuild my engine/store my nova over winter, ill hoover up and clean the windows, mow the grass happily in exchange lol

[joff-turbo-nova]

Been busy today...

Finally got the head stripped down ports cleaned out.

Next job was lapping in the valves which is a rather boring job but worth doing to get a good seal on the valve seats.

This is how the valve and the head started , note the nice and shiny ring around the valve and valve seat....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE047_zpsc395ff36.jpg


http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE048_zps5aa09ce1.jpg

Once lapped in, there is now a constant "grey" ring, where the faces have been ground together - job sorted only another 15 to do :eek:

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE050_zps785a676b.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE049_zpsfa50f0fc.jpg



The exhaust valves where a bit pitted as you can see here .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE051_zps8aa65bb3.jpg

But with a little extra work on the lapping process ......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE052_zpsf0c08602.jpg

Also had to remove two studs which had snapped off into the head. One washer, nut and migwelder later and the problem was solved....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE053_zps413c1a19.jpg

You put the washer over the stud hole and then start welding at the base of the stub, the washer protects the head. Once the weld is at the height of the washer, put the nut on and fill it with weld till it glows cherry red.

With all the heat this put through the stud, you just let things cool to just below red hot and then simply undo. The heat breaks down the crud on the threads making it easy to wind out.

After all the valves were lapped in next job was getting it all back together. 8 exhaust valves fitted....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE054_zpsdeada7e2.jpg

And then the inlet valves....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE055_zpsfc578997.jpg

Started on the camshafts and put the inlet one in, notice the cam caps are nice and clean...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE056_zps1705fca4.jpg

These are the exhaust cam caps awaiting a clean....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE057_zps7c5e5762.jpg

Next job tomorrow is get the exhaust cam fitted and then I can put the head on the engine and get the water pump and timing belt stuff fitted.

Joff

[Andy]

Have you marked up/are the cam caps marked? As its pretty important they go back where they came from..
Everything still within tolerance?
Rebuilding engines is indeed therapeutic.I have to agree.

Good work.

[joff-turbo-nova]

Have you marked up/are the cam caps marked? As its pretty important they go back where they came from..
Everything still within tolerance?
Rebuilding engines is indeed therapeutic.I have to agree.

Good work.

They are each numbered like on the C20XE engines which is handy !

End float was good and the gaps on the piston rings was bang on .

Joff

[joff-turbo-nova]

Update...

Got the exhaust cam on and then the head onto the block and torqued down. I was surprised at the tightening sequence, 40nm, 90 ° , 90° , 90° then 45° :eek:. I think the head stretch bolts have now lived up to their name lol

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE062_zpsa4d26a88.jpg

Then got on with getting all the timing gear and water pump back on....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE063_zpsfe9f3d3f.jpg

1st time round I was a tooth out, but got it on the 2nd attempt!

Then it was on with the covers and I put a set of both inlet and exhaust studs in and placed the gaskets ready for the manifolds.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE064_zps0bb1b972.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE065_zpsecbba1f4.jpg

Next job is to strip the engine out of the meriva and swap all the bits onto the new block.

Joff

[Spudly]

Good work Joff, you dont hang about do ya, i trust the back isnt giving you as much grief now and youre back up to speed?

[nova_niek]

Nice read Joff, well done. Rebuilding engines is awesome work. As said, very therapeutic! :-)

[MK999]

Looks good... not sure if it's different on what I assume is a Z18XE, but it looks like you might be missing a camshaft sensor? Goes under the top cover between the cams.

Not bad torque on those things too :d not the best I've seen though! BGA MLS gasket on a 106 gti... 80Nm, 90, 90, 90, 90!! I was sweating at the end lol

[joff-turbo-nova]

Looks good... not sure if it's different on what I assume is a Z18XE, but it looks like you might be missing a camshaft sensor? Goes under the top cover between the cams.



Yes you are right, this engine came without sensors, will need to swap things over from the other engine sitting in the Merv.

Joff

[joff-turbo-nova]

Right, today's update....

Got on stripping the Meriva, here she is looking a little nervous :(

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE068-1.jpg

After an an hour or so we were getting somewhere :-

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE069.jpg

Just after lunch I had it to this stage ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE070.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE071.jpg


With a large boot full of bits !

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE072.jpg

Then things slowed down as I needed to sort fiddly jobs like removing the drive shafts and getting the exhaust removed, both had never been removed so were somewhat difficult.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE073.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE074.jpg


Noticed that the exhaust is shot from the joint under the cat to the joint at the back box (its all one piece), so that's on the list of parts. Also noted that the sump on the Mervia has a oil sensor in it, the one on the new engine doesn't , so that will need to be unsealed from the block and swapped over once the engine is out.

Engine bed is next on the list to remove, already disconnected the roll bar, bottom ball joints, steering rack and track rod ends.

Just need to disconnect the gear linkage and then remove 4 bolts and its just the engine mounts and the engine is out!

Joff

[joff-turbo-nova]

And I need to clean the new drive!

[Markd89]

haha #the wife.

Good progress joff, will give you a ring sometime next week about the flocking

[fearless]

Looking at this picture

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE063_zpsfe9f3d3f.jpg



From memory - the position of the cambelt tensioner looks wrong - the allen key lug is normally at about 20 past !!!

I might be completely wrong but worth checking !!


Dave

[joff-turbo-nova]

Looking at this picture


From memory - the position of the cambelt tensioner looks wrong - the allen key lug is normally at about 20 past !!!

I might be completely wrong but worth checking !!


Dave

Dave,

I lined the pointer up to the 2nd mark for a new belt and that's where I locked off the tensioner - I will be double checking the timing again along with the tension once the engine is ready to be installed.

Cheers for the heads up anyway!

Joff

[joff-turbo-nova]

Quick update....

This arrived this week ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE075.jpg


An almost new alternator, only been on a vehicle for about a month before it failed its MOT and was scrapped - not bad for £15 off ebay !

More work tomorrow weather permitting - should get the engine out and the necessary bits swapped over.

Joff

[mowgli]

joff, get some cardboard from the shop for under that car.....or you'll kill your driveway blocks

[joff-turbo-nova]

Cracked on this morning and got the engine bed removed (4 bolts and it was out !) - notice the cardboard I had in my shed for this job....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE079.jpg


Then I got the engine crane out and got the engine mounts loosened off and dropped the engine out using my new engine leveller I got for my birthday ......


http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE080.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE081.jpg

I then pulled the engine into the garage and started stripping the parts. The exhaust manifold came off without too many issues.

I was changing over the camshaft sensor when I noticed that the engine mounts were different .....

Astra -

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE083.jpg

Meriva -

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE084.jpg


What is really a pain is that the cambelt idler sits on top of the mount which is great - cambelt back off again swap over the mounts :grr:

Also checked the tension on the belt again - the tensioner is in almost the exact same place from the old engine....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE085.jpg


And the new one......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE082.jpg

More stripping and swapping tomorrow after the Japanese Grand Prix .

Joff

[joff-turbo-nova]

Busy day today not too many pictures ...

Got on with swapping the engine mount around - cambelt off mount off, new mount on, cambelt back on and engine timed up again!

Once that was sorted next job was to change the sump for the meriva one with the sensor in - so I had to turn the engine upside down, no mean feat with the head on - just used the crane to lower it down ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE087.jpg

Had to unseal the old sump , clean off the sealant, clean the new sump up and resealed. Once swapped over used the crane to lift it back up again.

Then got the the exhaust manifold properly bolted on along with the new thermostat ......

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE089.jpg

Also swapped the starter motor over, then the big pipes that go from the back of the water pump along the piccolo tube and lastly the inlet manifold....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE088.jpg

I have taken out the injectors as I am having them cleaned at the local bosch fuel injection place, which is just round the corner from me which is handy !

More updates next week - my back needs a rest !

Joff

[joff-turbo-nova]

Some new CV's arrived today as the old ones were well past it ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE092.jpg

Also picked up the injectors today, all nice and clean - the fuel injection chap said the filter baskets had a fair bit of muck in them - so I think a new fuel filter needs to be on the cards too.

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE091.jpg

More updates over the weekend.

Joff

[mowgli]

joff, what are you doing with the old engine??

[joff-turbo-nova]

joff, what are you doing with the old engine??

Not really thought about it to be honest, it needs new rings and a good hone as a minimum due to the oil consumption previously.

It was either a) going on ebay or b) getting weighed in . If it doesn't sell as one lump then I will sell the head and the rest of the parts separately and weigh in the bits which don't sell.

Joff

[mowgli]

i might be interested in the crank, pistons & rods....the crank & rods might be some fun in my e16se...... or if i ever get it working, as an upgrade for my x16xe/x16xeL mongrel..

[joff-turbo-nova]

Today's update.....


The new exhaust got a coat of VHT paint on the welds just to make it last a bit longer .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE095.jpg


Got busy putting the injectors back in and then the loom and ECU back in place - a bit fiddly in places but we got there in the end ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE097.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE096.jpg

Then the flywheel and a new clutch was bolted on ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE098.jpg

I then got the gearbox covered in degreaser and then put on a little trolley and powerwashed clean.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE099.jpg

Took the opportunity to remove all the oil from the gearbox by removing the diff plate . Then cleaned everything thing up ready to reseal with a new gasket ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE100.jpg

Also put in a new slave cylinder in and changed the driveshaft seals whilst I was there.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE101.jpg

Got the gearbox mounted up to the block .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE102.jpg

And then craned outside to the car.....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE103.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE104.jpg

Bearing in mind I was on my own and rushing a bit because it looked like rain, the block was in and installed within 20 minutes !

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE105.jpg

Now sitting on the main mounts and this is where I called it a day due to the rain!

Forecast looks better for tomorrow so will crack on with the engine bed and exhaust.

Joff

[Vlietje]

Some good progress Joff! How's your back?

[joff-turbo-nova]

Some good progress Joff! How's your back?

It aches a bit at the moment , especially as I've been lifting the gearbox today. Nothing that a hot water bottle won't sort in bed tonight ..... sounds like I'm a right old f@rt !

joff

[joff-turbo-nova]

Got the driveshafts rebuilt this morning with the new CV joints ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE107.jpg

Then installed a set of new bushes on the roll bar. How you change these with the engine bed in situ I just don't know - the bolts were tight and the bushes fairly worn - just made sense to do them now.

Got the engine bed round to the car, and with the aid of two jacks finally got it in position. This took longer than getting the engine in ! . It was the angle of the steering rack shaft that was causing problems .....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE108.jpg

Need to do some house jobs this afternoon - it rained on and off anyway so no great shakes.

Need to change the fuel filter and then plumb everything back in. Shouldn't take too long as everything is standard.

Joff

[nova_niek]

Good going Joff. Well impressed. And keep your back warm!

[joff-turbo-nova]

Well, cracked on this weekend with the work ....

All the engine electrics were wired in and then I sorted all the plumbing and radiator out ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE111.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE110.jpg

Then sorted the exhaust which was a bit of a pain as the middle section was so big and heavy, but sorted in the end ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE112.jpg

Then got the fuel filter changed. The stupid connector on one side , decided to totally disintegrate which was handy. I had to splice in a bit of pipe which was more of an annoyance than anything ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE116.jpg

Got all the driveshafts put in and a new set of discs and pads from Vauxhall on trade club ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE113.jpg

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z18XE115.jpg

It was then in with the gearbox oil , engine oil and coolant . I poured a bit of oil in each of the cylinders to ensure a bit of lubrication and cranked it a few times without the plugs in to get the oil pumping round the engine.

I then put the plugs and coilpack back in and she started first time, albeit a bit smokey at first due to the oil in the cylinders.

After a few minutes the smoke cleared and it was running fine , top end was a bit tappety for a while, but once the oil warmed up and got all the air out of the lifters it was running really nice and smooth.

Put the headlights and bumper back on ...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Untitled-3.jpg

And then put it back down on the ground all finished ....

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Untitled-4.jpg

Will be going back on the road on the 1st November as it's SORN'ed at the moment.

Very happy with the results.

Joff

[Spudly]

Fantastic work as always Joff, ill be Paula will be happy to be out of the astra, is it turbo your meriva now then?

[Vlietje]

Wow! Some GOOD progress Joffy! All I did this weekend was painting two windows...

[joff-turbo-nova]

Fantastic work as always Joff, ill be Paula will be happy to be out of the astra, is it turbo your meriva now then?

She's been using my Merv (Lancelot) so has had her rear nice and toastie in the VXR seats ! In fact she says she wants heated seats in her Merv (another job to do!)

I've been lumped with the Shed (aka the Astra) . It's been a reliable steed so far, got me to Leeds and back last week without problems. Done about 2k in it so far. It's due its MOT in December and given the delays in getting Paula's sorted , I will have to get it through the MOT.

The whole front end clonks over bumps even after changing the roll bar drop links. The rear beam knocks too ! I already have roll bar bushes and bottom arms, so this will hopefully solve the front end issues, the rear I think needs new dampers as the bottom joints have worn. Nothing that a day in the garage won't sort with the windy gun !

Joff

PS Once the garage is tidy and I have shot of the old block then its Z20LET rebuild time!

[nova_niek]

Result! :thumb:

[Spudly]

Wow! Some GOOD progress Joffy! All I did this weekend was painting two windows...





All i did this weekend was drink lol

[Vlietje]

All i did this weekend was drink lol

+ rep!

[CorsaBBoomer]

And I kept you from your work lol


Nice work Joff :thumb:

[joff-turbo-nova]

Quick update....

Back on the road and taxed today, being the 1st of the month.

Had a slight problem, got to the end of the road, pulled out and then pop... grind grind as I turned left.

Grrr..... thought it was the inner CV popping out of the gear box but no ...

After I had pushed it back down my lane and got the wheel off the nearside the driveshaft had come completely out of the outer cv, busting the circlip on the way.

Fortunately I had spares and after 20 mins was back up and running. I visually checked the offside (a big mistake!) which seemed OK so off we went to get the tax disc.

2 miles up the road, guess what, the offside lets go and does exactly the same thing. This time too far to push so had to get Green Flag on the case. They were only in the next village, so 10 minutes later they arrive at the roadside and a further 10 minutes later I'm stripping the wheel off to inspect what's going on.

Again the circlip had come out of the groove and mangled and again I had a spare (my last one) . Another 20 minutes and all was fixed.

Gingerly (with some tow rope in the boot) I did a tour round the back roads for 15 miles to check everything was OK and I'm pleased to report that the driveshafts are now behaving as intended .

Not sure why this happened, maybe I didn't locate the circlips into the grooves in the CV's correctly on both shafts when I changed the CV joints , or whether the circlips failed.

All is well and I am taking it over to Bedale Saturday for a run out to check it over.

Joff

[joff-turbo-nova]

I'm pleased to report that the Merv has now covered 600 miles without problem - just dropped the oil out of it today and changed the filter over and put some more Vauxhall semi-syth back in.

Also treated it to one of these ...


http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET120.jpg

A magnetic sump plug, now in situ ...

http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET121.jpg

Joff