View Full Version : Meriva Z20LET project.
davie300zx
11-01-13, 09:57 PM
Hi all,
Quick update , not much done over Christmas, however after looking at the dash , the VXR carbon effect trim panel that goes across the dash seems to clash a bit with the silver centre console.
As my new VXR steering wheel has piano black inserts I thought I would make the centre console piano black as well .
I sourced a replacement control panel to begin with....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/dash1-1.jpg
Then rubbed it down removing all the symbols and numbers, then sprayed with primer and GM Sapphire black ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/Piano1_zpsa672f9aa.jpg
I originally tried to source some vynal stickers to replace the symbols and numbers, however due to the very small size this was not an option.
Next choice was some decals, which worked sort of but due to the transparent nature you could hardly see them,
http://i2.photobucket.com/albums/y15/joff-turbo-nova/Piano3_zps2e09314b.jpg
so have gone with the third option .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/Piano2_zps0369b202.jpg
Just blank (and laquered)..... and I will have to remember where all the settings are !!
Joff
Bit footery but you could repaint siver ,put new graphics on repaint black
Then take stickers off ...new silver detail....re-laquer !!
Piano black and silver decals .....
Try here ......
Cree 501 LEDS (http://www.ebay.co.uk/itm/221128604162?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649)
Joff
Awesome, cheers Joff, theyre perfect for what im wanting, now to figure out where my old cav headlights went so i can rob the sidelight holders lol
joff-turbo-nova
12-01-13, 09:28 PM
Quick update...
Picked some parts up from GM today ....
VXR bumper lower grille.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1253.jpg
Fog light surrounds, fog grilles and headlamp washer jets ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1254.jpg
Not too sure how the jets work at the moment , I was expecting them to be like the mk3 Astra ones with the jets outside. It seems these are more like the pop up ones on the mk5 Astra's . I may need to rethink this option and look at alternatives to graft in place as sourcing the rest of the mechanism may be somewhat difficult !
Got all the valves lapped in and then set about putting it all back together. I'm pleased to say all 16 valves are now back in......
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1255.jpg
I'm now in the process of pulling apart and cleaning the hydraulic lifters. I've done one, only 15 to go !!
Joff
joff-turbo-nova
17-01-13, 09:30 PM
Another update....
A rather large UPS package arrived today . I started pulling it open....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1258.jpg
And after a lot of packaging (which is good!) I found this gem all the way from Poland .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1259.jpg
As described there is the smallest of nicks on the lower nearside and a very small crack on the nearside corner.
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1262.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1260.jpg
All of which can be very easily repaired , all that is missing is the steel support bar that lives under the offside headlamp, which I will rob off the other bumper!
Joff
joff-turbo-nova
20-01-13, 10:32 PM
Evening all....
Quick update on this weekends work - got the cylinder head all rebuilt and torqued down on the studs, you do it in three stages, 25 ft/lb, 50 ft/b and then up to 75 ft/lb , just oil the threads and put some oil or grease on the washers - job sorted ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1263.jpg
Then put the oil cooler on - I had previously cleaned up the oil pipes and sprayed them matt black, the first of the silicone hoses were put on as well .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1264.jpg
I also put in the two union bolts which have threads tapped into the end to take the feeds for the oil pressure gauge and oil temp gauge....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1266.jpg
Then on with the inlet manifold and throttle body (which was rather grotty and needed a really good clean out) ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1267.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1268.jpg
I was going to strip the standard intake pipe ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1269.jpg
But then remembered I had one of these ......
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1270.jpg
I need to find out where these go and in which order - I suspect the feed and return to the heater matrix - not sure on the other one?
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1271.jpg
That's it for now - awaiting a couple of gaskets and seals from Autovaux which should be here next week.
Joff
nova_niek
21-01-13, 03:04 AM
Good progress Joff, always enjoy reading your updates. Very useful info on the stud extraction method! :thumb:
joff-turbo-nova
21-01-13, 09:35 PM
Been doing a bit of research and have narrowed down the options on the pipes...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/COOLANT1.jpg
If you think its wrong let me know
Joff
I'd say it's right, as the hottest water will be from the head... So looks right.
joff-turbo-nova
24-01-13, 08:34 PM
Quick update...
I got the timer board yesterday and was expecting something like this.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/timer1.jpg
However it arrived in kit form like this.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1272.jpg
So after digging out the soldering iron and solder , 20 minutes later it looked like this....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1274.jpg
Much better !
Tested with the bench power supply and I can vary the length the pump stays on from about 0.2 seconds to about 5 seconds before it turns off. There is a variable resistor which I will play with and set it up right once installed on the car.
The pump for the headlamp jets arrived today - a bit more beefier than the normal washer pumps...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1275.jpg
Hopefully some more seals and gaskets will arrive from Autovaux tomorrow so I can crack on with the engine at the weekend.
Joff
novacabrio
24-01-13, 11:50 PM
What's the timer for?
joff-turbo-nova
25-01-13, 07:27 AM
What's the timer for?
It's so when you pull your windscreen washers on, the headlight washers only come on for a short period as they are high pressure.
Joff
Can I have the part number for the pump joff please? And an average cost?
joff-turbo-nova
25-01-13, 09:14 AM
Can I have the part number for the pump joff please? And an average cost?
Part number is 90508709 - found on some Vauxhalls but more common on Saabs .
This one came from ebay and was £12 inc postage. New they are about £45 if I remember correctly.
Joff
Just got a new one for £28 delivered
joff-turbo-nova
27-01-13, 07:48 PM
Another update...
Got busy with more building of the engine and got round to getting the turbo mounted on the new studs....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1305.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1303.jpg
Took me a while to figure out how to fit the pipes as I needed to change the LEH one round to the LET version but we got there . Got all the oil pipes sorted and got a restrictor bolt inserted at the same time.
Got the cambelt back cover on and the camshaft sprockets and the idlers and tensioner - just need a water pump from Autovaux which should be here next week with some other seals and gaskets along with the popup headlamp parts I need for the OPC front bumper...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1304.jpg
Put the heat shield on and put the rocker cover on temporarily to seal the top end from foreign debris...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1306.jpg
Got the aircon pump installed (from a 20k Astra VXR) and cleaned the cam covers ready to get the belt on next week....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1307.jpg
Also took some advice and have bypassed the throttle body with the water hoses as the LEH doesn't run this arrangement , just the LET version....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1308.jpg
Then put the engine wiring loom into place on the injectors ...
However I just need to figure out where all these connect !!
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1310.jpg
Joff
Amazing as always Joff, i love your work mate :d
joff-turbo-nova
28-01-13, 08:50 PM
A nice box arrived today from Autovaux....
A water pump and some rather rare popup mechanisms for an OPC bumper along with the washer bottle and neck...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1311.jpg
Lots of seals and gaskets....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1312.jpg
And here's the mechanism for the pop ups - activated by water pressure apparently !
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1313.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/headlampwashers.jpg
Joff
Pop up washers are very cool.
joff-turbo-nova
02-02-13, 10:00 PM
Quick update....
Got the water pump installed and the cambelt on and engine timed up - got it first time which was nice ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1314_zps7e684e86.jpg
(This is not on the marks if you are wondering, I had just finished spinning it around 8 or 9 times to double check tension and timing)
Then got the 120A Astra VXR alternator on ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1315_zps84ee1e4c.jpg
And got the bottom pulley and auxillary belt on with the tensioner.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1316_zps8c814829.jpg
I have started sorting the back plate for the vaccum box - needed stripping and de-rusting - I have primed and sprayed matt black again and will reinstall in the morning.
Also been working on the piano black parts of the dash - this is the vent surround partially rubbed down - the plastic has small dimples which need rubbing flat...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1315_zps61ccbeeb.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1318_zpsa5526a56.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1316_zps418c7843.jpg
Then masked up....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1319_zps7b5cfd5c.jpg
And a couple of coats of primer, black and gloss and its come out like this...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1321_zps8688e4fc.jpg
Quite happy with the results, I will crack on with some more dash parts next week. Now that the engine is nearing completion I will need to think about pulling the M32 gearbox apart and replacing the bearings :eek:
Joff
mk3 vinny
02-02-13, 11:29 PM
first time iv seen this thread and it is very impressive
joff-turbo-nova
04-02-13, 10:13 PM
first time iv seen this thread and it is very impressive
Cheers for the comment, its just having the time, patience and the right tools !
Anyway, I was surfing the web today and noticed that quite a few of the Z20LET boys have had trouble with hard to pinpoint running problems and a lot of the problems related to a crimped earth on the engine wiring loom, so I set about doing the earth mod / modification ....
First is to locate the correct part of the loom, the actual crimp is located in the thick part of the loom where it crosses the side of the cylinder head just under the plug for the coil pack - with the gearbox off and the engine not in a car it makes taking the pictures easier . The crimp is just after where the two sets of wires branch off from the main loom, one for the lambda, and one for the coolant temp sensor here ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1324_zps08bad90d.jpg
First job is to strip off the plastic outer coating ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1325_zps65925ef4.jpg
Then carefully cut and peel back the inner covering to reveal the wires themselves....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1326_zpsfba62319.jpg
Have a dig around and you will find a heat shrink joint like this (which has an adhesive inner lining)....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1327_zpse36ff877.jpg
I found putting a cut in one side and heating it up with a gas torch like this had it removed in seconds ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1328_zps0340fd44.jpg
And here is the offending crimp that needs sorting ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1329_zps4b78c64f.jpg
So I cut it out and then twisted the pairs of wires together .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1330_zps463c94a4.jpg
Then found some suitably thick brown wire in my box of bits and soldered in the extra wire ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1331_zpse5158fff.jpg
I had already slid down the wires some heat shrink prior to soldering so moved this up into position and used the gas torch to heat it all up again to get the glue flowing ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1332_zpsd2e2e57d.jpg
And then taped everything back up again and put the outer covers on and made everything neat & tidy....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1333_zps79a7bf05.jpg
Job sorted and this should give no issues in the future.
Joff
Nova_Tek
04-02-13, 10:51 PM
Great work as always.
Handy tip that, will be doing it on the zaf
Well worth doing if it's as troublesome as you say.
It's funny, because those in the know always say OE crimps are far superior to solder.
What happens to the crimp, corrosion??
joff-turbo-nova
04-02-13, 11:39 PM
Handy tip that, will be doing it on the zaf
Just find the wire for the coolant sensor and follow this back into the main loom and the crimp is about 2 inches down towards the ECU round the back of the loom.
Joff
joff-turbo-nova
04-02-13, 11:47 PM
Well worth doing if it's as troublesome as you say.
It's funny, because those in the know always say OE crimps are far superior to solder.
What happens to the crimp, corrosion??
I think they flex and break and give an intermittent connection which leads to really strange ECU error codes to do with lambda sensors and airflow meters which gets you going in completely the wrong direction to fix the problem.
Vauxhall have now even recognised this as an issue and have issued a field remedy to be used at the dealers to solve problems - Field Remedy 2006
Joff
I think they flex and break and give an intermittent connection which leads to really strange ECU error codes to do with lambda sensors and airflow meters which gets you going in completely the wrong direction to fix the problem.
Vauxhall have now even recognised this as an issue and have issued a field remedy to be used at the dealers to solve problems - Field Remedy 2006
Joff
Crazy isn't it? You would imagine when taped into the other wires, then bound together, then braced further with conduit, that it wouldn't be able to move enough.
I'm glad for you and other ZLET owners that there is a known fault and it's simple to repair.
Nothing worse than an intermitent electrical faulf on a fairly complex system!
joff-turbo-nova
10-02-13, 10:04 AM
Well I took a voyage into the unknown yesterday and started stripping the M32 six speed gearbox down for a bearing replacement.
The box I had sourced was "apparently" a low mileage item, however given the fact I had no proof of this I thought it prudent to open it up and change the bearings, given that this is a weak point of these gearboxes.
Anyway not having done many gearboxes I took it up to my Dad's in Whitby , as he put it "he's stripped more boxes than I've had hot dinners" .
So cracked open the case and found that the bearings were not too bad to be honest....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1338_zps56c05705.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1339_zps95f49e1e.jpg
There was none of the pitting on the top three bearings you normally get with when these gearboxes start to fail.
As we had a full set of new bearings waiting to go in we cracked on. We looked at how the selector shaft was positioned ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1341_zpse86c40f6.jpg
Then removed it along with the two gear clusters and the input shaft leaving just and empty case with some bearing races to remove.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1347_zpsee3ab344.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1348_zps02ff190b.jpg
We didn't have a specialist puller with really narrow legs to get under the bearings so came up with plan B .....
We got the welder out and tacked in some threaded bar in a T arrangement then just pulled them out by winding a nut down on some thick steel bar across the casing....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1350_zpsd3f59e7a.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1349_zpsbe2dc305.jpg
A few turns of the spanner and it was out ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1351_zps9a792da8.jpg
Then set about the others in the casing, the other gear shaft was welded and pulled and the input shaft bearing we managed to get the puller legs on it and tap it out with a hammer.
The other end of the casing we warmed up with hot water and pulled the bearings out with the puller without too much drama.
The input shaft has a collar threaded on the end which was mighty tight but came off ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1352_zps45ad5a13.jpg
Leaving the shaft ready to pull the bearing off .The other end of the input shaft again just needed the bearing pulling off and an new one sliding back down and tapped home . Put back into the casing ready for refitting..
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1354_zps71043815.jpg
We inserted the bearing races into the upper gearbox casing...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1355_zps347729d6.jpg
Next up was the upper gear cluster, which has bearing at both ends. In an excellent design feature you have to strip the complete shaft to get to the bottom bearing that sits in the casing next to the diff. So we started stripping....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1353_zps42f31de1.jpg
We got to the bottom of the shaft with the syncros coming apart at one stage and pulled the old bearing off.
At that point we ran out of time as my Dad is a full time carer for my Mum and needed to go and help out inside.
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1356_zps73551a28.jpg
This is my dad's garage where all the magic of building stuff in my younger days happened - we reshelled the Nova here, rebuilt a 1.6 8v and a 2.0 16v engine in here...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1357_zps08be9a65.jpg
At the moment my dad is doing a lot of work with washing machines (there's about 15 in there with another 20 in the back garden under cover!!)
Next up is rebuilding the upper gear shaft and then stripping and rebuilding the lower shaft, which is the same design of cogs, syncros and retaining clips.
Also found these diagrams handy knowing where the retaining clips were ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/m32-upper_zps514ac61d.png
The originals are here :-
M32 gearbox exploded diagram (http://www.diagnostics.org.uk/2010/01/m32-6-speed-manual-transmission-1-9-cdti-vxr/)
Cheers
Joff
joff-turbo-nova
16-02-13, 10:09 PM
Quick update...
As the engine is about ready and I'm not in a position to get to my dad's to finish the gearbox off I have set about with a number of other jobs on the Meriva.
First up was the Opel fog light conversion .....
First job was to remove the rear cluster....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1361_zps3bc12d53.jpg
Then the lower part which exposed the dummy fog light like so.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1362_zps736555e9.jpg
Which left the bodywork stripped ready for the new wiring ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1364_zps1b0d7340.jpg
Found a plug in my box of wires which fitted which was handy...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1363_zpsca56f27a.jpg
Then realised to get to the wiring loom on both sides behind the trim panels I would have to remove all of the boot storage assembly....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1365_zps0d2a0249.jpg
Trick is to take the top part of the trim off first which goes round the window which exposes a hidden screw ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1367_zps2802642e.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1368_zps10618479.jpg
The wiring for the meriva runs down each sill to the rear so there was no option of picking up the right wire on the nearside loom , so had to strip out the other side exposing the right wire ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1369_zps0d40e7dd.jpg
Which is black with a blue trace....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1370_zps88656644.jpg
I then ran a wire from one side to the other under the rear sill and found a handy earth point for the brown wire ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1374_zps8449de32.jpg
The wires were fed through an existing rubber gromit to the new Opel cluster....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1372_zps8406e2b5.jpg
I then reconnected the battery and switched on the fogs as trial run ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1376_zpsbab00ad2.jpg
And then put it back together to make sure everything still works ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1378_zpsb2ff7b8b.jpg
Took about 3 hours to do, mainly because I wasn;t sure how the trim panels came apart - took about 20 minutes to put back together !
Also cleaned and painted the gearbox casing this week as it looked a bit tired ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1359_zpsce110b50.jpg
Joff
Is there no end to your skills. M32 box conversion is something ive been pondering
Where the fogs not there to start with?
joff, have you ever considered doing a restoration of some proper old classic?? as your attention to detail is incredible
joff-turbo-nova
17-02-13, 02:44 PM
Where the fogs not there to start with?
The fogs on a Meriva are like the nova - just on the offside - however the cluster is there on the nearside but just a dummy lens.
It just annoyed me that both clusters didn't light and I was aware that Opel version was the same but in reverse (like the Corsa A) so sourced an Opel fog light from German ebay and it was sorted !
Joff
joff-turbo-nova
18-02-13, 08:23 PM
Quick update...
Changed over the clocks and steering wheel to the Meriva and Astra ones respectively with LEDS's in the clocks ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1379_zps3225f9ca.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1386_zps600c5101.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1394_zps629010f0.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1395_zps1f56d53b.jpg
The steering wheel was a straight swap, however the clocks were another matter.
First off I didn't have the code from the original car and secondly I didn't understand the relationship between the dash and the immobilser system. All I got on the dash was a car and a spanner flashing at me ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/Z20LET/spanner_zps542813c5.jpg
So after a bit of research on the web I got my opcom out and had a fiddle .
The basic steps are :-
1. Find the code of the dash in the Eeprom
2. Unlink the dash from the code back to an "unmarried" state
3. Marry the dash to the car using the car security code
Job sorted - all starts and works as it should - reset the mileage whilst I was there as well!
Continued with the piano black theme and sorted the headlamp unit from this ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/switch1_zps1f4e5d5a.jpg
to this...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1387_zps81f7baf1.jpg
Also arrived today were some more breather hoses from Roose...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1392_zps8b572613.jpg
That's it for now.
Joff
Dash bits and clocks too much better dude.
novalovingned
18-02-13, 10:29 PM
Love reading this build thread. Attention to detail is superb as usual.
novadave24
19-02-13, 05:30 PM
this is looking good mate love the vxr parts :)
joff-turbo-nova
23-02-13, 10:05 PM
Quick update....
Got all the bits rounded up for a satnav conversion on the dash ....
One TomTom Start60 ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1398_zpsc87e7a76.jpg
One modded binnacle cover.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1399_zps89e817ec.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1400_zps0d2b24ea.jpg
Put the two together and hey presto , one OE looking sat nav....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1401_zps86117f60.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1402_zps78f8ecb4.jpg
I put in into the Meriva to see how it looked ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1404_zpsc5657610.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1405_zps6fdc5e02.jpg
I then had to think where to put the existing display as I do like to see the outside temps - I was considering next to the interior light just infront of the rear view mirror, but the LCD unit is just too big. Next option was the cubby hole just under the ash tray , so after a bit of hacking , screwing and glueing we have this ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1411_zpsbae9f181.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1413_zps26081523.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1415_zpsec8649bd.jpg
Turned out OK, just need to get some multi core cable to extend the plug down to the lower dash and this unit has 22 (yes 22) wires going to it - good job I have a new soldering iron station arrived this week !
Joff
Southie
23-02-13, 10:16 PM
It's all the trick bits and jiggery pokery that makes a great build even better, love the OEM look of both Joff :cool:
Love the built in satnav.
Lovely job on the sat-nav mate.
I'd be lost without my soldering station!
joff-turbo-nova
01-03-13, 08:09 PM
Found this on the kitchen side when I got home, I wonder what it could be ......
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1416_zpsb18201de.jpg
Seals and bearings , handy .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1417_zps944c6c76.jpg
And a nice Quaife ATB - nom nom ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1418_zpsf9fe2d6c.jpg
Joff
joff-turbo-nova
02-03-13, 12:55 AM
Very nice buy.
There was a group buy one VXROnline using a Alfa tuner (Alpha's also run the M32 box)
Joff
joff-turbo-nova
10-03-13, 09:51 PM
Right had a busy day yesterday .....
Got the old diff off the crown wheel ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1424_zps1ad075e6.jpg
And the new Quaife unit installed ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1421_zps1a49b21e.jpg
Rebuilt the upper gearshaft .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1422_zpsd6c63dea.jpg
And started stripping the lower shaft ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1423_zps5bd7daf4.jpg
Then pressed a new bearing onto the end and then reassembled it and sat it in the casing ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1425_zps8f65a805.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1426_zps538bb432.jpg
The needed to figure out how the selector forks went back in along with the selector rod ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1427_zps42b63d2c.jpg
And sealed the casing up with the correct sealant and bolted it all up and put the diff in the back and all was good ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1428_zpsc3d9dfac.jpg
Many thanks to my Dad for helping out with the pullers and the hydraulic press !
Spent today tidying out the garage as I was struggling to find any tools under the mess !
Normal work will resume shortly. Next on the list is get the flywheel mounted along with the clutch and cover and then on with the gearbox.
Cheers
Joff
Good job on stripping the box.
joff, how the feck did you manage that on mother's day?????
joff, how the feck did you manage that on mother's day?????
The wife sounds well trained from the sound of things :)
joff, how the feck did you manage that on mother's day?????
The wife sounds well trained from the sound of things :)
joff-turbo-nova
11-03-13, 08:11 PM
joff, how the feck did you manage that on mother's day?????
Work on the gearbox was actually done on Saturday at my parents - so I got to see my mum near mothers day , unfortunately due to a brain aneurism 4 years ago she doesn't really know one day from the next.
Sunday was spent potting up plants in the morning, tidying the garage out then cooking Sunday lunch (at tea time!) so I still did some domestic duties to keep in with the Mrs !
Joff
Good stuff.
Damn, I was in Guisbourough over the weekend, would have popped over for a mince if I knew you were over Whitby way lol
joff-turbo-nova
17-03-13, 10:02 PM
More updates...
First job was to correctly tension the cambelt doing it anti clockwise - job sorted....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1430_zps8edf61d2.jpg
Then I secured a precat decat from the e of bay last week - was a bit tatty so sprayed it with VHT paint and mounted it on the turbo....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1431_zps1ca01c3b.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1432_zps5f4c5398.jpg
It was then on with the crankshaft oil seal. Now these are a little tight to get in and a rather large diameter.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1439_zpsef3f4f69.jpg
I was struggling to find anything I could use to press in the seal in the garage, but wandering through the kitchen I saw this....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1440_zpsb72f86fe.jpg
And low and behold it fitted .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1441_zps37a7f23c.jpg
So a couple of screws later it was removed and pressed into action - literally !
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1442_zps88097880.jpg
Next up was the new Luk flywheel with new bolts sourced from GM followed by the clutch and cover....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1443_zps96ae7c58.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1444_zps523ea71e.jpg
Needed to put in a new release bearing slave cylinder on the gearbox....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1437_zps793f9a63.jpg
And put the new Meriva VXR mount on the gearbox - Meriva VXR black, Astra VXR silver.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1438_zps004ca79e.jpg
It was then on the with gearbox. Now having a bit of a bad back I didn't really feel like lifting the best part of 50kg on my own and trying to get the splines lined up on the clutch and input shaft, so I improvised with the engine crane and a couple of ratchet straps....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1445_zpsf5eccc39.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1446_zpsfcafc009.jpg
After a bit of up and down and in and out it eventually slid on nicely on the splines so I nipped up all the mounting bolts and its now ready to install once the weather gets a bit more reasonable.
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1447_zps5c579aa3.jpg
Also sorted the mounts out ready to go on as well...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1449_zpscfebc59c.jpg
Joff
Awesome work Joff, give me a shout when you want the engine going in, ill gladly help if it means keeping your back risk free from injury again mate :thumb:
Oh and dont let Paula read this update either lol
joff-turbo-nova
17-03-13, 10:30 PM
Oh and dont let Paula read this update either lol
The scales were cannibalised when she was at Church this morning - all put back together before she got back so she's none of the wiser .... errr lets just hope she misses this !
Joff
Lol, i adore your sneakiness Joff, utterly fantastic lol
joff-turbo-nova
23-03-13, 08:08 PM
Update...
Whilst the weather is grim I've been doing some inside jobs .
First up is the white line anti roll bar which has had a hard life :-
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1459_zpseaf2e33a.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1460_zps1d1d8b69.jpg
So out with the flapper disc on the angle grinder and after 20 minutes we had this :-
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1461_zpsba39b730.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1462_zps771b659b.jpg
Got the rust eater out to clear any missing patches and then gave it a coat of hammerite which looks a lot nicer....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1463_zps27350939.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1464_zps0af9642b.jpg
Will give it another 2 coats to give it a chance to resist stone chips and the like .
Joff
joff-turbo-nova
24-03-13, 07:48 PM
Started to have a go with all the brackets for the roll bar today .....
A bit tatty to begin with.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1475_zpsd1109eb8.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1482_zpscc9cb782.jpg
Once stripped they looked at lot better ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1483_zpsbc0750ad.jpg
And the first coat of hammerite .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1484_zpsea68c831.jpg
Need to sort out some stainless steel bolts and washers and once the painting is complete its ready to fit .
These arrived this week too ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/fkshockers003_zps9bbfe036.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/fkshockers004_zps2dc743be.jpg
Something a bit more upmarket than the Rokkor cheapo coilovers I have already (which I got in a job lot of stuff last year), which are now on ebay at a reasonable price if anyone is interested !
Joff
joff-turbo-nova
06-04-13, 09:24 PM
Been a bit busy with the nova of late - last weekend the I needed to adjust the handbrake , pulled it out of the garage and put it on the (sloped) drive. Chocked the wheels, walked back into the garage, looked up and saw the nova rolling down the drive and across the road. Crunched into a rather solid wall opposite and mullered the back bumper and cluster.
However a week later and after the bumper had been to the bodyshop all is well again ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030110a_zps99eacd61.jpg
This also arrived last week, a nice stainless exhaust with a sports cat ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030111_zps5782e709.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030112_zpsc0c3be16.jpg
Once its warmed up slightly I may get round to changing the rear seats for the leather VXR ones, whilst the seats are out I need to wire in a new fuel pump and also the rear electric windows and sort the new electric mechanisms in the rear doors.
Joff
Good to see the nova is all shiney again Joff, when do you think you will be dropping the turbo'd lump in, id love to go for a jolly in it with you to see what its like when its all done :d
Ouch on the Nova front, coilover look good tho.
staggy_gsi
07-04-13, 11:44 AM
Dont have much luck with the nova do you mate, was it not the front end and a grazed knee last time?
Never mind, at least its shiny again!
joff-turbo-nova
07-04-13, 12:32 PM
Dont have much luck with the nova do you mate, was it not the front end and a grazed knee last time?
Never mind, at least its shiny again!
Its trying to escape at every opportunity !!! After 24 years its decided it wants to live elsewhere - as its in my Will its not going anywhere !!
Good to see the nova is all shiney again Joff, when do you think you will be dropping the turbo'd lump in, id love to go for a jolly in it with you to see what its like when its all done :d
As I'm doing this on the drive, only when the weather is a bit warmer - its nice today but have other jobs on at the moment - next week is cold again so not for a while. You can give me a hand squeezing it in if you want !
Joff
No problem, let me know when and ill be there, happy to help :d
joff-turbo-nova
15-04-13, 10:02 PM
Quick update...
Got the roll bar all painted up with 3 coats of hammerite and all the brackets and bushes put back together with stainless steel nuts and bolts .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1563_zpse6252348.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1564_zpseb7ab5ef.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1567_zpsf5fef1fa.jpg
I then cracked on with getting the VXR bumper rubbed down ready for a respray. Split the bumper in two so the paint gets right into the joints properly....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1568_zps21293f42.jpg
Needed to repair the area that had been sprained by something ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1570_zps78a4fa8d.jpg
Whilst the filler was going off I started on the upper section.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1572_zps5c155d0a.jpg
Need to finish off the rubbing down and fix the crack on the nearside corner under the headlight.
Joff
joff-turbo-nova
28-04-13, 07:57 AM
Update from yesterday ...
Got the VXR bumper all rubbed down and repair and ready for paint ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030125_zpse9fb78b2.jpg
Then got the Meriva jacked up ready to remove the rear beam...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030123_zps416d7702.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030124_zpsa787c975.jpg
Then removed the rear beam and got it onto the bench to start stripping...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030126_zps05149cde.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030127_zps79dda1bd.jpg
Plan is to change the rear discs to Astra VXR items, change the brake lines to braided hoses and change the bushes to poly ones.
So stripped down one side and started to size up how to remove the rear bushes - the Hanyes manual was ever so helpful by stating a "special tool" was needed which was only available at the dealers - pish !
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030128_zps260b844b.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030129_zps16d03046.jpg
So hacked off one side of the bush and gave it a good beating to no avail ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030131_zpsf72ca222.jpg
So at this point gave up with the bush removal and just stripped the other side , so now we have a bare beam with just two bushes to remove...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030130_zps02c9a076.jpg
I haven't go a socket big enough to pull through the bush or one to press it through from the other side , so plan B is going to be the blow torch !!
Joff
staggy_gsi
28-04-13, 10:50 AM
I always burn the rubber off, and cut through the metal outer with a hacksaw. Should then just tap out...
joff-turbo-nova
28-04-13, 07:52 PM
Well here goes rear beam bush removal 101 for a Vauxhall Meriva or Astra ....
First of all you need a source of heat , something like this...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030137_zps75fe61a7.jpg
And an old screwdriver or similar....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030138_zpsac4c5ebb.jpg
Start heating up the rubber ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030132_zps92221167.jpg
I discovered the best way to get the rubber burning was to direct the heat towards the metal sleeve in the middle of the bush, get this really hot and the sleeve actually pops itself out of the rubber and has generated sufficient heat to get the rubber burning nicely..
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030144_zpsd124b7c6.jpg
Let the rubber burn , occasionally prodding it with the screwdriver to get rid of the ash...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030134_zpsb91ad5e8.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030135_zps50058efe.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030136_zps75d31585.jpg
You should now be left with something like this...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030139_zps010f3a0b.jpg
You then need to hacksaw carefully the aluminium sleeve - be careful not to cut into the beam itself..
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030140_zpse10ffed0.jpg
Once cut you should be able to just tap out the aluminium sleeve and be left with these ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030142_zpsae78ac57.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030143_zps775a777d.jpg
And there you go !
Next up was to jet wash and wire brush down the beam and give it a couple of coats of hammerite ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030146_zpsd897309a.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1030148_zps77b09d7f.jpg
Need to get a second coat of paint on it and then I can start rebuilding it!
Joff
Awesome work Joff, im willing to bet you were hoping for the destructive method to be required lol
BENDOGGER
28-04-13, 08:47 PM
That garden needs some loving too mate lol
joff-turbo-nova
29-04-13, 07:23 AM
That garden needs some loving too mate lol
It's on the radar for bank holiday weekend !
Joff
Vlietje
29-04-13, 10:23 AM
It's on the radar for bank holiday weekend !
Joff
WTF, you've been on gardening leave for 6 months... :tard:
Good progress on the rear beam, our curry most have given you some extra strenght! :thumb:
Keep it up!
joff-turbo-nova
04-05-13, 09:04 PM
Todays progress...
Built up one side of the beam with the poly bushes, VXR discs, back plates and calipers and braided brake hose from HEL (thanks Russ!) .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1578_zpsda1a0379.jpg
Then sorted the other side .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1576_zps20af2255.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1577_zps2821e156.jpg
Got the beam mounted loosely.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1581_zps4cae1596.jpg
And put on the whiteline RARB .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1582_zpse3eaf7e0.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1584_zps7d56462b.jpg
Just need to nip everything up tight in the morning, put the springs and dampers in and bleed the brakes .
Looks like it may be a bit lower at the back as well, here are the new springs - and that's with the adjuster near the top !!!
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1579_zps8cd0668d.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1580_zps5b55ee3b.jpg
Joff
nova_niek
04-05-13, 09:14 PM
Cool, really coming along now Joff. Loving the new springs!
joff-turbo-nova
06-05-13, 05:16 PM
Got busy today mounting everything thing up tight, reattaching the brake lines and bleeding the calipers. Sorted the handbrake , put the springs in and reattached the dampers.
Lowered it back down and it kept going and going....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1637_zps94324310.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1638_zps94fd7ddc.jpg
I think that is about the limit to how low I want to go, if anything I may put it up 10mm or so.
The springs are not fully compressed so there's still some suspension travel (just!)
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1639_zpsebc74518.jpg
Joff
BENDOGGER
06-05-13, 06:53 PM
I hope you have spent a few hours on that back garden pal
joff, those wheels look tiny...lol
you are going to catch out a lot of people when its done
joff-turbo-nova
06-05-13, 10:03 PM
I hope you have spent a few hours on that back garden pal
Oh yes, the wife made sure of that ! All tidied up , just need to power wash down the paving and wall to get it clean and its sorted!
(see I do other things apart from car tinkering !)
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1640_zps14653d16.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1641_zps7977726f.jpg
Joff
Thats sitting really nice
joff-turbo-nova
16-06-13, 11:02 AM
Quick update....
Started pulling the front end apart - wheels bumpers and headlights first....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1688_zps351523df.jpg
Ably assisted by next doors moggie....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1690_zps45004367.jpg
Then off with the rad pack .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1692_zpscda96c1c.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1693_zpsc603bcc1.jpg
Then Spud rolled up and helped me with the hubs and brakes whilst I disconnected all the electrics and pipes and rear bulkhead .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1694_zps303802c3.jpg
We whilst it was threatening to rain we had a mince with Spuds van to get rid of a kinked intake hose....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1695_zps211c001f.jpg
And then it rained lots which didn't help ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1696_zpsf94f5854.jpg
Last job of the day was remove the exhaust system which was a bit of a pain on the back box, but a bit of brute force and heat helps.
Next job is the gear linkage, engine bed and then the engine is ready for removal.
After that, before the new engine goes in I need to change over the gear stick to the six speed cable version and run a new return fuel line back to the tank.
Cheers
Joff
joff-turbo-nova
22-06-13, 11:12 PM
Quick update....
Got the engine bed off this morning .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1698_zpsd640ff48.jpg
Then got the engine off its mounts and down onto a dolly.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1700_zps9aedf129.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1701_zpse9b2f8bc.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1702_zpsfa4cdfa8.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1703_zps37dde6e4.jpg
And then it rained - lots so gave up and took Patrick to a birthday party!
Also noticed that there is not a return fuel line on the car, and where you access the fuel pump there is no connection for a return pipe which is handy! I have some nylon pipe which will do for the underfloor pipework and some rubber fuel hose to go at each end - just ordered some -6 AN bulkhead fittings which will allow me to put in my own return - looks something like this ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/an-8-an8-an-8-90-degree-bulkhead-fitting-autobahn88-ft040-a08_zpsf12bfe94.jpg
Joff
joff-turbo-nova
29-06-13, 09:08 PM
Quick update...
Due to dropping my 2ft power bar on my toe yesterday, things have been a bit slow today.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1706_zpsaa900899.jpg
Anyway got the new driveshafts cleaned up along with the hubs....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1714_zpsa619bca9.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1715_zpsf4bff3ba.jpg
Then got on with changing the gearstick mechanism to cable ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1710_zps1cf4eb5e.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1708_zps5235de9f.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1707_zps12823c7e.jpg
Also put in the hard nylon return fuel pipe , just need to mate it at the fuel tank end to the new unions that arrived this week...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1709_zps0040ed95.jpg
Then had some bad news - although I have the right idle shaft for the M32 box, the support mounts I have , Astra GSI, Meriva VXR and Astra Cdti will not fit, so now on the hunt for a Z20LEH rear driveshaft mount (GM part no 13106996 if anyone has one spare!). Grrr ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1711_zpsb7a67f77.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1712_zpsbfcafcad.jpg
However the good news is the front gearbox mount fits - just need to reweld the mounts on the subframe in the correct position ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1713_zpsf02257da.jpg
Toe now throbbing so off to rest !
Joff
joff-turbo-nova
30-06-13, 08:26 PM
Cracked on today....
Woke up this morning to this....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1724_zps67035dfb.jpg
But it didn't put me off trail fitting the Z20LET into my Meriva ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1716_zpsd35a3200.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1717_zps6da9fb63.jpg
The engine side mount seems to work OK, but the gearbox side seems not to line up....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1719_zpsa85dcd87.jpg
Seems that the standard gearbox mount won't mate, I need a either a Meriva VXR or Meriva 1.7 cdti mount to get it to fit.
Looking at the position of the gearbox , alternator pully and aircon pulley, things seem to be very tight . I may need to move the aircon pipes back a bit to give a bit more clearance.
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1720_zps561963f4.jpg
Whilst I'm waiting to round up the rear driveshaft mount and gearbox mount I will be working on the subframe - need to put poly bushes in the lower arms and on the ARB along with grinding off the old gearbox mounting lugs ready for them to be rewelded.
Cheers
Joff
How come you've kept he rear bcs joff?
Wear some Steel toe capped boots!
joff-turbo-nova
01-07-13, 02:51 PM
How come you've kept he rear bcs joff?
Just keeping it standard (ish) - I know there is a way of bypassing the vac box, but I wanted to get it up and running before I start doing anything out of the norm.
Wear some Steel toe capped boots!
I was only checking the washing machine and was walking past the bench when I knocked off the power bar ! Hindsight is such a wonderful thing !
Joff
Isnt it just lol
Ah didn't realise it was an unrelated misadventure lol
Hindsight is such a wonderful thing !
http://www.youtube.com/watch?v=cqkI691dxNg
lol
That south park clip makes me giggle everytime lol
Just keeping it standard (ish) - I know there is a way of bypassing the vac box, but I wanted to get it up and running before I start doing anything out of the norm.
I was only checking the washing machine and was walking past the bench when I knocked off the power bar ! Hindsight is such a wonderful thing !
Joff
Its the most simple mod there is joff and means you get full boost in all gears rather than just 4th-5th
joff-turbo-nova
04-07-13, 10:16 PM
Quick midweek update....
Got stripping on the subframe and removed all the steering rack and roll bar (trial fitted poly bushes on the roll bar)....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1727_zps8746714b.jpg
Then got the pressure washer out and cleaned down the subframe.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1726_zps575f0f61.jpg
And cleaned off the lower arms and knocked out the bushes, just need to repaint the arms and put the new poly bushes in ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1725_zpsd19ead98.jpg
Just need to grind off the old front gearbox mounts and clean off the paint ready to tack in the new front mount lugs once my gearbox mount arrives which should be tomorrow.
Joff
Looking good Joff.
Keep up the good work and put some steel toe cap bos on next time.
Fatboy288
11-07-13, 04:01 PM
Hi im doing a meriva z20let and just wondered what you have to do with the ecu plug on meriva loom? Thanks
joff-turbo-nova
11-07-13, 09:02 PM
Hi im doing a meriva z20let and just wondered what you have to do with the ecu plug on meriva loom? Thanks
Same as what you have to do with the corsa C - you have to look at the wiring diagrams of both looms and move about 10 wires around in the ECU plug. You also need to wire in the barometric sensor which is on the car loom (not engine loom) and the rear BCS (boost control sensor) is on the charging loom.
Warren G on Corsa-c forum will do you a guide for a small fee.
If you have the bits of loom out of the donor vehicle it makes it a lot easier.
Put up a work in progress thread - lets see how you are doing !
Joff
joff-turbo-nova
22-07-13, 10:06 PM
Update from the weekend...
Got the subframe and removed the front lugs and prepped it ready for welding...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1728_zpsb3090183.jpg
Got the new VXR engine mount and everything fits as it should (sort of) ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1779_zps91fbd60e.jpg
However its really tight, no , touching the aircon pipes so will have to move them up by about an inch to clear the alternator pulley...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1788_zps194e7e8b.jpg
Got the rear mount sorted , this bolts onto the standard fork on the engine subframe...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1782_zpseb363792.jpg
I then hit a bit of a problem with the engine bed mounted up - the front gearbox mount actually hits the subframe and won't let the engine tilt in the right place. Thinking cap on.... light bulb came on - just turn the mount the other way as I was going to have to weld on new lugs to the subframe anyway...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1789_zps2448b525.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1792_zps5146a77e.jpg
Lugs tacked on in the right place....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1793_zps5284ed53.jpg
Next I removed the subframe and went to town with the welding to ensure they were up to the job, then a couple of coats of hammerite and we're ready to reinstall ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1794_zpsb7869e30.jpg
Next up is getting the steering rack and roll bar back on the subframe and it reinstalled into the engine bay.
Joff
Ref this, can you not just remove the huge spacer thats in there?
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1788_zps194e7e8b.jpg
joff-turbo-nova
22-07-13, 10:22 PM
Ref this, can you not just remove the huge spacer thats in there?
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_1788_zps194e7e8b.jpg
Fraid not - its a VXR alternator rather than a GSI one, the body of the alternator sits nearer the inlet manifold hence the spacer type thing on the pulley - removing this will mean the belt will just catch the camcover as it will sit about 15mm too far in towards the inlet manifold. The pulley is in the same place as the GSI one, so swapping it over won't make any difference either.
I have a cunning plan .. in the above pic the black plastic bracket sits on one of those barbed spikes - like the one showing at the top of the pic. I'm going to make a spacer with a flat bit of steel and another barbed spike about 3/4 inch long which will space the pipes up by about 3/4 which should give sufficient clearance. Might be a bit of trial and error on the length - fortunatley the pipes have a rubber insert on the rear bulkhead which makes moving them around easier - phew!
Joff
Ah i see. Your idea sounds very good.
Fatboy288
25-07-13, 11:44 PM
I cant seem to get my hea aroun the wiring on meriva iv done a corsa z20let twice but this is completely different some colours dont match cant get fuel pump or injectors to work any help much appreiciated
joff-turbo-nova
28-07-13, 10:44 PM
I cant seem to get my hea aroun the wiring on meriva iv done a corsa z20let twice but this is completely different some colours dont match cant get fuel pump or injectors to work any help much appreiciated
Wiring is on my things to do list - when I have it sorted I will be able to adviser further - sorry !
Weekend update ....
Got the bottom arms all polybushed up - the Meriva and the Corsa C share the same lower arms - just used Corsa C poly bushes...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040145_zps3bcae333.jpg
Then sorted rebuilding the engine bed - put the steering rack and roll bar back in - poly bushed the roll bar whilst I was rebuilding....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040146_zpsba411e6b.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040147_zps53e64780.jpg
Then reinstalled the engine bed and hit a problem. Some how the brackets I welded on were about 3/4 inch in the wrong place which pushed the engine over and the alternator into the chassis leg. Not good. Well out with the grinder and cutting discs and after a while faffing on with some new brackets, hopefully these will now do the job....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040151_zpse3e70d13.jpg
Sorted the raiser bracket for the aircon pipes too. Here's the bracket I made up....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040152_zps0ea997b4.jpg
Installed on the chassis leg ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040153_zps39b41a5a.jpg
And lots of clearance on the pipes which is a good thing....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040154_zpsf7e16c9a.jpg
Then started on the gear linkage and notice that the selector bar just catches the gearbox mount, so will have to grind off some of the bar for clearance - joy !
Joff
joff-turbo-nova
29-07-13, 12:33 AM
More good news - just been digging around on online EPC to find that the Meriva version of the M32 has a different selector shaft than the Astra and Zafira versions ! Joy.
However I have found out how to remove the top of the shifter so at least I can fettle it with the grinder off the car!
Joff
joff-turbo-nova
03-08-13, 11:24 PM
Quick update....
Been a tail of two halves over the last few days.
Managed to get the shifter arm off but then pushed it the wrong way on the shifter mechanism and it seemed to lock up . No amount of pushing or giggling helped so I needed to crack open the gearbox to find out what's happening .
So engine out again ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040167_zpsffc5ffbc.jpg
Gearbox end casing off ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040168_zpsdcf21554.jpg
Seems that the shifter had over rotated and pushed the reverse syncro beyond its normal stops and push it into the space below the 3/4 gear clusters . I pulled the gear cluster - put the syncro and the spring loaded ball bearing tags back together as you can see...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040165_zps8958ffc5.jpg
Here is the space the syncro was pushed into....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040166_zps85c690bd.jpg
So top tip don't over rotate the shifter if the gear linkage cables are not attached !
So after that little drama the gearbox went back together and then I reinstalled the engine again !
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040170_zps17548924.jpg
And worked on the shifter grinding more clearance which it now doesn't catch ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040169_zpse2a27dc9.jpg
You can see the arm is getting a little thin....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040171_zps0e36b9f5.jpg
So I'm going to weld a support plate to the other side tomorrow.
Cheers
Joff
Good work getting the engine in, the balance weight is rather big and oddly placed..
Fatboy288
04-08-13, 07:25 PM
Got my wiring sorted in the end hours with two wiring diagrams all in now on mounts and running just waiting for hubs to turn up will ad video soon
joff-turbo-nova
04-08-13, 10:42 PM
Well another day of good news bad news ....
Good news is the driveshafts fit , got the driveshafts in and hubs , ABS sensor , discs and brakes on with braided hoses ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040175_zps707694a5.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040177_zps9aaf088a.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040181_zps9c1ba557.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040180_zpsd8ee0cd6.jpg
Bad news is that Astra G dampers / coilovers won't fit on a meriva ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040178_zps6f49060a.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040179_zps54bc535f.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040176_zps5999da2e.jpg
The hub lugs are too wide and the hole pattern is all wrong and the roll bar mounting point is 30mm too low.....
However the got the shifter mechanism beefed up , painted and installed ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040173_zps970cab17.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040182_zps6d461adc.jpg
Joff
joff-turbo-nova
04-08-13, 10:44 PM
Got my wiring sorted in the end hours with two wiring diagrams all in now on mounts and running just waiting for hubs to turn up will ad video soon
Have you got any pics or a work in progress thread? Just wondering where you mounted your ECU ?
Joff
joff-turbo-nova
05-08-13, 09:35 AM
Just sourced this Corsa C kit which will be here later this week so all things still go....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/Spax_zpse752e225.jpg
Need to ask the coilover experts - will the Corsa C springs be up to the job with the extra weight of the Z20LET & M32 or should I swap over the Astra G springs onto the Corsa C dampers???
Joff
If the springs fit I personally would fit them.
nova_stee
06-08-13, 07:54 PM
I look forward to reading this thread every weekend the attention to detail is awesome
Southie
06-08-13, 09:27 PM
Do GAZ do a coilover kit for these Joff?
joff-turbo-nova
06-08-13, 11:34 PM
Do GAZ do a coilover kit for these Joff?
Missed out on some Gaz Corsa C ones that were on sale a few weeks back on CCUK forum. Spax used to be cheap cr@p when I first got into modding, however over the last 10 years they seem to have improved the quality quite a lot. The brand new Spax RSX kit is £600 which is well above the budget coilover zone!
Anyway todays update ...
Got the nearside lower arm, hub, brakes, calipers and braided hoses all installed ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040189_zps878ba3fa.jpg
Then started on the exhaust - wasn't too sure the Toyo exhaust would fit as its an Astra G item , however I am glad to report that it fits just fine !
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040188_zps0b830669.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040186_zps40cc6636.jpg
However the rear lambda sensor is a little too close to the exhaust tunnel wall ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040187_zpsb73ca549.jpg
So have ordered an L shaped adapter which will change the angle by 90° and give sufficient clearance.
Beyond the stainless front section and cat I am planning to get a stainless system all the way back to the Irmscher rear box , however to get the car roadworthy and to an MOT station (was due its first MOT February just gone) I have started to cobble together parts of the old exhaust .
The front section finished where the middle box used to start to first job was to take a precut flange and fashion the exhaust to fit - going from 2.5 inches to 1.5 inches. I just flared the ends and welded in triangles in the gaps !
The other end will mate to the part which curls round the petrol tank and over the rear beam to the backbox. Again I have flared it to accept similar diameter pipe. I will tack it in plate tomorrow and fully weld it up along with the hangers for the middle mounts (which are just dangling out of the rubbers at the moment !
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040183_zpsed30adcb.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040184_zps7a326bef.jpg
Also got sidetracked into removing some hedging ..... 7 leylandii trees chopped out , another 22 to go !!!
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040191_zps1ae2be3c.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040190_zpsd5a1cfa0.jpg
Joff
Great work, crazy idea with a meriva tho haha
Looking good dude. shame about the Astra coilovers not fitting.
joff-turbo-nova
07-08-13, 09:57 PM
Right a bit more holiday work....
Got the exhaust all welded up with the support brackets in the right place....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040196_zps578c4abc.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040197_zps3e6fa680.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040199_zpsb4dc5b24.jpg
I then fitted it all together so will now pass an MOT, however going from a 2.5 inch front pipe to a 1.5 middle section won't be doing anything for the power figures. I have a contact who makes up bespoke stainless exhausts so will be getting him to sort out the mid pipe , and possibly change the entry pipe on the rear box too. It might be on the tad bit loud without a middle box!
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040209_zps0ac84477.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040208_zps18d8c894.jpg
I then cracked on putting in some water hoses, breather pipes, fuel lines and the plugs and coil pack...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040204_zpsed3d1ee6.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040205_zpsbc70709a.jpg
I trial fitted the boost pipes and put the rad pack in to see how much room there is behind the radiator near the turbo and in front where the intercooler is going...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040206_zps18982074.jpg
A fair bit of room behind the rad pack......
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040203_zpscf31924d.jpg
.... not so much up front .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040202_zps74186b70.jpg
Trial fitted the intercooler with front bumper and have come across the problem that the bumper is hitting the intercooler - need about 3 cm to clear ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040201_zps6a5d379e.jpg
However looks nice with the intercooler in place....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040200_zpsfc44c846.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040207_zpsa00f49df.jpg
Joff
this is awesome! i want one lol
Jeff16v
07-08-13, 10:27 PM
Cracking work Joff, updates every day, off with the kids?
joff-turbo-nova
18-08-13, 05:50 PM
Cracking work Joff, updates every day, off with the kids?
Yep, just had a week in Welsh Wales so no updates for a while - back at work in the morning ....:cry::cry::cry::cry:
Anyway after more hedge bashing today I swapped over the coilovers for the Corsa C ones, good news, they fit .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040563_zpsba5c0fd1.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040565_zpse81fee62.jpg
Also got the lambda sensor adaptor installed which now gives sufficient clearance on the exhaust tunnel....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040566_zps49e0c5f7.jpg
Next job is see if I can get the rad pushed back to give more clearance for the intercooler.
Joff
Vlietje
18-08-13, 08:12 PM
Result Joff! Take me for a spin next time we're going for a curry!!
corsakid
18-08-13, 08:40 PM
Awesome job
nova.mike
22-08-13, 03:53 PM
Awesome updates! Spax coilovers are the **** too :)
joff-turbo-nova
24-08-13, 09:31 PM
Mincing about last week around the o/s headlamp....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040597_zps7e03fd98.jpg
.... I found this plug ......
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040596_zps4173e91f.jpg
..... which I discovered the headlamp washer pump fitted nicely into....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040601_zps73cf2be5.jpg
I was under the impression from the EPC pics that the headlamp washer bottle fitted to the n/s chassis leg like so ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/headlampwashers.jpg
However this seems to be incorrect - so ordered up the correct in chassis leg nuts ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040598_zpsa196cb38.jpg
And hey presto one fitted washer bottle ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040600_zps978fa5bb.jpg
Complete with pump ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040604_zpsdfe90c68.jpg
Next comes a bit of a problem (not major), the OE route takes the filler neck to the side of where the OE air filter housing normally lives ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040605_zps9824cd78.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040607_zpsa5504eae.jpg
However this is where the intake pipework will go into the top of the turbo, so I will have to dig out some pipework out of the spares box and relocate it up the near the tank vent valve where there is plenty of room.
Also picked up some VOF28 oil filters today - I noticed that the standard VOF93 was sitting a bit close to the lower arm ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040593_zps2d4de5e9.jpg
So found a replacement filter, the VOF28, as you can see about an inch shorter....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040595_zps39d2fd95.jpg
Which fits quite nicely without causing concern.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040594_zps112a439e.jpg
Cheers
Joff
Vof98 handy one to know...
Vlietje
25-08-13, 06:59 PM
VOF28 Bennyboy! lol
Good progress Joff! Should be ready before we come over again! :thumb::thumb:
do the vof 28 fit the 20xe's to?
joff-turbo-nova
25-08-13, 08:44 PM
do the vof 28 fit the 20xe's to?
Yes they do , and Z18XE engines, and C20LET ..... you get what I mean!
Joff
joff-turbo-nova
26-08-13, 09:21 PM
Quick update,
Finished mounting the intercooler , made up some brackets with some thick alloy strip I had knocking around and bolted them up with stainless bolts .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040615_zpsbc011edc.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040616_zps06c61f18.jpg
I now have a "little" space behind the bumper, however I thing the grille will need to be mounted slightly further forward ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040608_zpsfb421f3e.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040609_zps09251439.jpg
Also figured out how to fit the headlamp washers .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040610_zps9f732846.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040612_zps1c53d774.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040611_zpsc5aa6c56.jpg
The seem to just sit wedged onto the bumper, however once the bumper is sprayed I plan to stick down with sikaflex to make it more secure....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040614_zps657f1a6a.jpg
Sorted the path of the intake .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040618_zps4e0b327c.jpg
And also the cold air feed pipe , however I have now noticed this cuts off access to the oil dipstick ! I was looking at fitting a C20XE one next to the oil breather pipe at the gearbox end of the block, however the sump is a different shape and won't work with the Z20LET sump.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040617_zpse21c02a0.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040622_zps87d17664.jpg
Worked out the route for the turbo to intercooler pipework as well.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040620_zps0f525ea1.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040621_zpsf33d8971.jpg
All this pipework is all bespoke and is just taking a lot of time to measure and cut and re-measure and refit, but we are getting there !
Joff
joff-turbo-nova
27-08-13, 09:42 PM
Problem solved with the dipstick access .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040623_zpscd6784ae.jpg
Just a bit of judicious manipulation (bending a fair bit) and all sorted !
Joff
Topmanbeny
28-08-13, 09:12 PM
Really like the idea of this and top work sir looks a great build
joff-turbo-nova
28-08-13, 09:42 PM
Just got my log book back today with the new engine number updated - the great thing is with the cars based on C02 emissions, irrespective of the engine size, the tax is based on the original engines (Z14XEP) emission levels - £145 for the year - yay !
Joff
Nice one Joff and even better result with the tax. Happy days.
joff-turbo-nova
31-08-13, 09:28 PM
Quick update .......
Lots of fiddly jobs sorted today - sorted out a new set of earth leads, alternator to body, inlet manifold to battery -ve and ecu to body.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040624_zps09f62206.jpg
Then extended the wires for the airflow meter (4 wires) , MAP sensor (4 wires) and then the reverse light switch on the gearbox (2 wires).
Next up was then sorting where to mount the ECU. Both the engine loom and body loom had sufficient reach to get to the inner wing next to the battery tray, so this is where it ended up....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040626_zps6b5aa5fa.jpg
Needed to take a notch out of the battery tray ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040631_zps72fe334f.jpg
Which allowed the looms to reach the ECU.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040630_zps32740e51.jpg
And the battery tray to sit correctly.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040628_zps7659d943.jpg
And fit the battery in without catching.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040627_zps5413526e.jpg
Just now need to sort the rest of the wires out (that you see in the background) and play around with the pins in the body ECU plug to make things work as they should.
Also awaiting a coolant pipe (top hose from rad to thermostat) in order that I can put all the rad pack back in permanently and then start filling the fluids (coolant, engine oil and gearbox oil). Need to bleed the brakes and clutch as well.
Sorted out a padding for the back of the intercooler as well to stop it rubbing against the aircon rad - amazing how handy an old mouse mat can be !!
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040625_zps45a66f89.jpg
Joff
Like what you've done with the ECU. Tidy.
joff-turbo-nova
31-08-13, 11:21 PM
Like what you've done with the ECU. Tidy.
Wasn't quite enough room to get the alloy back plate on the also holds the barometric sensor as well - will make up a separate bracket for that tomorrow - looks quite OE all the same!
Joff
maddogdaz666
31-08-13, 11:35 PM
Love your work, it all looks very well thought out, not just a "that'll do" approach. Top work. Have some rep :thumb:
joff-turbo-nova
01-09-13, 08:05 PM
Today's update .....
Trialled the washer jets to see how they pop up .....
http://s2.photobucket.com/user/joff-turbo-nova/media/P1040636_zps64bf1fe5.mp4.html
A very fine high pressure spray !
Next job was to fill the gear box , I'm using Fuchs Titan Sintofluid which seems to come highly recommended for the M32 boxes...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040635_zps4b08caeb.jpg
Also filled the engine oil up with GM semi synthetic for a 500 mile run in , before switching to fully synthetic .
Sorted the final routing for the filler next for the headlamp washer bottle....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040638_zps3f4c6328.jpg
Made up the bracket for the barometric sensor, its now living on the side of the battery tray....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040639_zps62aacff8.jpg
Prior to filling the engine oil I finished off fitting the oil pressure and oil temp senders for the pillar gauges ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040641_zpsa4572600.jpg
Need to finish the wiring off for the body ECU plug and get all the aircon pipes all tightened up.
After that I will need to remove the rear seats as I need to change the fuel pump in the tank. The seats need to come out anyway as I'm changing them for VXR leather ones.
Cheers
Joff
joff-turbo-nova
17-09-13, 04:13 PM
Right quick update. Things have been a bit slow due helping my dad sort out stuff since the passing of my mum on the 5th September.
Anyway, managed finally to get all the pipework , intercooler and pipes all reinstalled in the final places....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2517_zpsedf07081.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2518_zps80929e9a.jpg
Also got a alloy spout for the cool air feed for the air filter......
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2519_zpse6e58f79.jpg
Also sorted all the wiring out including wiring in the barometric sensor. I tidied all the wiring up and reinstalled the battery tray and battery ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2520_zpsbda934f7.jpg
I also refitted the top firewall and scuttle panel and wiper blades, it all fits without issues !
Also managed to source about a month ago a complete boot for a mk1 Meriva that runs a spare wheel as I wanted to get one installed. Out with the polystyrene ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2515_zps3052960a.jpg
Spare wheel cleaned ready to go in...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2516_zps139a9173.jpg
The spare wheel bracket is already fitted , just needed some cushioning and a bolt down mechanism....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2521_zps5fe0cb16.jpg
And then put in the rest of the trim ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2522_zps5aadd7a8.jpg
And the spare wheel ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2523_zps99c4cc68.jpg
Started taking the rear seats out which is a real pain , but having removed them from the wife's Meriva I remembered how to slide the seats around (back forward AND left and right!) to get access to the bolts. The rear seats are in 3 parts, each part is bolted down with 4 T40 bolts .
All this to get access to the top of the fuel tank to change the pump!! (and put the leather VXR seats in as well !!)
Turned the ignition on today just to see what lights came up - the fuel pump primed, and I found I seem to have a leak between no4 injector and the fuel rail which is a bit of a downer. Fortunately the fuel rail is easily accessible in the engine bay so will investigate shortly - the injectors were cleaned before installation, however this was 5 months ago so they may have dried out - I'm going to get a full o ring set for all 4 injectors from the Bosch place down the road from my work and change them all just to be sure !
Joff
joff-turbo-nova
17-09-13, 04:14 PM
Well got a bit done before the rain came down ....
Finally got all the rear seats out - amazing how much crud accumulates under your rear seats when you have kids!!!
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2524_zpsa8d04b00.jpg
Lifted the flap to find the top of the tank - note no return pipe fitting - I have one ready to fit once the tank is empty....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2525_zps74d38b36.jpg
To access the tank there is a big metal band around the cap, very much like the band you crimp round the CV boots, after unclipping this I found that the tank was brimming full (whoops!)
So I had to get another plug on the pump, a 12v power supply and use some cans to decant the excess fuel - saves me having to fill the Astra up in the morning !
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2530_zps942265b8.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2529_zpsea7e9720.jpg
Got the tank emptied, then it rained which has created a halt to proceedings !
Joff
joff-turbo-nova
17-09-13, 04:15 PM
Had chance between the driving rain to hook up the laptop to the car to see what the state of play was. Whilst I was there I turned on the headlamp washers in the BCM !
Good news , only one fault code - bad news - looks like my wiring may be to blame !!
It's to do with the barometric sensor and is coming up with P1105 "Barometric Boost pressure sensor short to battery - present" ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1105_zpsfad7f59d.jpg
The baro sensor has 3 wires which has been connected as follows :-
Pin 1 - wire at pin 53(body ECU plug) cut and directed to Baro wire on pin1
Pin 2 - spliced into Pin 5 (body ECU plug)
Pin 3 - Moved pin 45 to pin 23 (body ECU plug) and connected directly to pin3
Error is there with the barometric sensor connected or unplugged.
Any help on where the issue lies would be appreciated ! (Original engine is a Z14XEP)
Joff
Southie
17-09-13, 09:04 PM
Is this any help Joff?
http://ecat24.com/catalog/part/1/8/600/2542/26897/
corsakid
17-09-13, 09:18 PM
A wire is connected to a 12v source, instead of an Ecu 5v feed,
joff-turbo-nova
18-09-13, 12:48 PM
I have spoken to WarrenG on Corsa-c.co.uk about this (as I was working from his wiring guide) .
I need to reinstall pin 45 and check the other connections to ensure they are the correct way round as he suspects the positive and ground feeds are the wrong way round.
So Saturday morning I will be stripping the wiring back and having a good dig around to see what the issues are. It will be something quite straightforward I'm sure.
I have picked up a set of seals for the injectors and will change these as well.
Once these are done and the fuel pump changed I should be good to crank it over and get it started.
Cheers for the assistance
Joff
joff-turbo-nova
22-09-13, 09:08 PM
Quick update....
Got the fuel tank emptied and eventually (after a lot of fiddling with 4 screwdrivers) removed the fuel pump housing.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040676_zps18c59bb7.jpg
Removed the standard fuel pump and replaced it with the new walbro pump .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040677_zpsefee1e11.jpg
And then plumbed in the return pipe in the same place as the plastic casting has a hole....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1040678_zps4a533157.jpg
I found the fuel leak , one of the unions on the fuel rail wasn't nipped up so this was sorted and saved me having to pull out the rail and injectors.
Rechecked the wiring , reinstalled Pin 45 and used a spare pin out of the astra plug to put into pin 23 . However the Barometric sensor fault remained.
Not to be put off, I removed the plugs and cranked over the engine and after a while I got 80 psi which was nice !!
And then finally after reinstalling the plugs and coil pack .....
IT RUNS !!!
Hurrah !
However it only ran for a short time before I switched off as the exhaust was blowing from the V band - after inspection it seems that I have omitted to get the aluminium gasket which creates the seal. This is getting ordered in the morning !
And finally thanks for the help from my dad who popped over at the weekend :thumb:
Pip pip
Joff
Topmanbeny
23-09-13, 02:42 PM
awesome , i want one lol
joff-turbo-nova
24-09-13, 01:18 PM
Quick update...
Now this is important for all those attempting conversions with the newer style Vauxhall ECU's.
I was on a mission to find some pins for the body loom ECU plug on the Meriva which looks like this :-
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1050001_zpsafcc3622.jpg
So went to the local scrap yard here :-
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1050005_zps0c8a18df.jpg
And had a look in their yard ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1050004_zpsc545e3f5.jpg
Only to discover they had in no Merivas - grrrr ! However upon looking around I found out something quite important when repining the ECU's for Z20LET/LEH conversions - there are two types of plug which internally are different.
I found the correct plug on a Vectra C here :-
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1050002_zpsf95fb97a.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1050003_zpscb96fbd6.jpg
On looking further in the yard it seems that the Corsa C's are fitted with the Bosch style plug :-
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1050008_zpse8fe4b6b.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1050009_zps69d6df07.jpg
However my Meriva and the Vectra C's have the Delphi type plug :-
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1050010_zps3c6cd81a.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1050011_zps825433c8.jpg
Although the Bosch pins fit in the Delphi plug, the don't seat all the way down correctly , however the locking pin still goes all the way through the plug.
So top tip if you are repining make sure you match up the different makes of plug !
Will have a play with the plug at the weekend which will hopefully eliminate some of the fault codes and issues I have.
Joff
I would scrap a mondeo pick-up as well lol
joff-turbo-nova
24-09-13, 03:50 PM
I would scrap a mondeo pick-up as well lol
Never really noticed that as I was concentrating on finding the Vauxhalls which were right down the far end near the fence at the end.
Joff
Never really noticed that as I was concentrating on finding the Vauxhalls which were right down the far end near the fence at the end.
Joff
I usually try my hardest to avoid them. lol
Conversion is coming on well, mate.
Shoulda known that dump had nothing new in there lol
I was in there a few months ago.My mate manages it.
"any mk5's astras in?"
"you on drugs,Andy?" lol
Shoulda known that dump had nothing new in there lol
I was in there a few months ago.My mate manages it.
"any mk5's astras in?"
"you on drugs,Andy?" lol
Heroin isn't it?
I'm amazed to see a mk1 Mondeo that hasn't ended it's days on the oval. lol
Southie
24-09-13, 06:41 PM
Interesting findings Joff, looking forward to seeing which pins differ between the two.
Funnily enough i was in there on sat and saw that mundano too lol
http://i8.photobucket.com/albums/a36/spudly01/20130920_121419_zps8965e92b.jpg
http://i8.photobucket.com/albums/a36/spudly01/20130920_121430_zps18c394a4.jpg
Good work on the car though Joff, glad you ended up going as i almost certainly wouldve got you the wrong plug, and probably the one from the wrong bit of loom too :eek:
joff-turbo-nova
28-09-13, 10:07 PM
Quick update...
Got a seal and new V band fitted and bolted the exhaust up.
Good news , after changing the round pins to square ones all the fault codes have now disappeared, the only electrical issue now remaining is that the fan kicks in 15 seconds after turning the engine on and will stay on constantly. Warren G is looking into it for me. And no exhaust leaks either
Noticed once the engine had warmed up I had an oil leak though - not good....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1050013_zps295ddf68.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/P1050014_zps4136b84e.jpg
It initially looked like the crank seal behind the flywheel which would have been a real pain to fix as the easiest way would have been an engine out job to change it. However upon further inspection this afternoon after a clean and another run up to temperature, I found a dribble down from the sump gasket - phew !
I backed off the sump to gear box bolts, then slightly backed off about six of the sump bolts and then re-tightened the sump bolts and then nipped up the gearbox bolts . Ran back up to temp and no leak :d:d:d:d
Just need start finishing off a few things like nipping up the CV joint nuts and putting in split pins, tightening the rear axle and RARB up .
Upon the advice of my dad, I'm swapping out the rubber hoses in the petrol tank for nylon ones like these - less likely to react to the petrol over time...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/c87d54ab-1d9b-45a4-ac21-2a425afc7792_zps82b1b6e8.jpg
A job for next weekend. Need to go to Pirtek and source some pipe and clips next week.
Tomorrow its starting to put the interior back together and bolt up the steering column to the rack!
Joff
Good work mate and glad its nearly sorted. Well done in getting it to fire up.
joff-turbo-nova
29-09-13, 09:02 PM
Not much done today, but did a video ...
http://www.youtube.com/watch?v=VkNuTw29DYU&feature=youtu.be
Joff
sounds sweet mate, top work
nova_niek
01-10-13, 09:49 PM
Wow! Impressive work Joff. Keep it up mate. Have some +rep. :thumb:
Vlietje
01-10-13, 10:18 PM
Bow down for the Tinkermeister! Hats off to you Sire! You just scored a curry from the Dutch boys!
Sorry to hear that your mother passed away matey. Makes things like Nova's and engines so irrelevant...
So good to hear it running mate.
Well done.
joff-turbo-nova
06-10-13, 10:24 PM
Well small update....
Dropped the tank out of the car today to work on changing the rubber pipes inside to nylon ones I sourced from Courtenays - I'm glad I took my dad's advice , as even though the tank had only about a gallon in , the pipes had already started to disintegrate, and that's only after 2 weeks....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2576_zps2645b823.jpg
So fitted the nylon pipes and put the tank back into the car.
Sorted putting the battery tray in and neatened all the wiring up - just need to sort out how to stop the fan kicking in all the time - Warren G is on the case!
I also sourced some new badges , which I ordered about 4 weeks ago - due to the bespoke nature they took longer to come through. My Meriva is not a VXR, however it does have an XP Irmscher styling kit attached , so we have these ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2570_zpsadbfb82e.jpg
Made from real carbon fibre ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2571_zpsdaf18f33.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2572_zps000bbe1f.jpg
One each for the door and one for the tailgate - made by a really handy chap here :-
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2569_zps06754d9c.jpg
That's it for now - just awaiting a new ball joint for the steering rack (had to "borrow" one for the wifes meriva this morning) and it will be ready for a spin.
Joff
Amazing how quick the fuels eaten the pipe away. Badges are cool, better than VXR ones, but i'm not a fan.
Kev Turbo
08-10-13, 07:28 AM
. Badges are cool, better than VXR ones, but i'm not a fan.
Confused.com
The thought of what the car is makings the badges cool. But i don't like badges and stickers...
joff-turbo-nova
13-10-13, 10:32 PM
Hi all ,
Quick update ...
Got the front end back together temporarily for the MOT next week. Took it for a quick drive up and down the road and noticed a speed variable thrumming noise from the front end . This got me a bit concerned thinking it was driveshaft or bearing related !
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2597_zps78b1008f.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2596_zps22e4797e.jpg
However I got it in the garage and up on axle stands and ran the engine in gear for 20 minutes to bed things in and clean the brake discs up and then took it again for a quick up and down the road, and the noise has almost gone , which is good YAY !
Must have been where the pads have covered the discs and where they have rusted slightly, making a lip, creating the thrumming noise. A 17 miles blast up to the MOT centre should clean them up, especially as there's 3 miles of dual carriage way with 3 roundabouts which should give some high speed brake cleaning action.
Fan is still kicking in , and if I remove pin 45 it comes up with a cooling module error, which when I disconnected the 3 relays in turn still doesn't power the fan or clear the fault code. So I think I will get one of these kits which is an in line thermostatic switch which should solve the issues :-
http://i2.photobucket.com/albums/y15/joff-turbo-nova/revotec_zps44580d34.jpg
Cheers
Joff
Looking good Joff, is it going to BCC for the mot, i hope it doesnt throw a fan belt like the nova did on the last roundabout lol
joff-turbo-nova
14-10-13, 09:35 AM
Looking good Joff, is it going to BCC for the mot, i hope it doesnt throw a fan belt like the nova did on the last roundabout lol
Poly V FTW !!!
Vlietje
14-10-13, 01:01 PM
We're coming over again this Saturday, you better have it finished then boy! lol
joff-turbo-nova
18-10-13, 12:59 PM
Good News - its passed it MOT -hurrah !
No advisories per say, but it seems I have more than just a minor oil leak . The MOT tester said it was coming from "behind the starter motor" which means its either the oil cooler connections or higher up and the rocker cover gasket.
Will need to investigate further. Off to see the chap who's doing the exhaust in the morning and on the way back calling in at the spray shop to sort out a date and price for the front end spray work.
Joff
joff-turbo-nova
05-11-13, 07:31 AM
A quick update...
After trundling around for a few hundred miles with the coilovers on, I've decided that for an everyday car its just too stiff especially on the B roads round my village, where it skips and bounces due to the rough roads, so ordered these last week which rolled up today ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2657_zps274173bb.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2660_zps50f672f9.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2661_zpse7c18d48.jpg
I have a full set of Meriva VXR dampers waiting at my local Vauxhall garage to be collected at the weekend so this should make the ride firm but very usable.
Will update further at the weekend.
Joff
TeddyThom
05-11-13, 03:27 PM
Awesome as always Joff. Guy at work has a meriva vxr... Lovely looking car! Sounds pretty awesome and he says it goes like stink. I've yet to persuade him to let me have a go in it! lollol
Awesome as always Joff. Guy at work has a meriva vxr... Lovely looking car! Sounds pretty awesome and he says it goes like stink. I've yet to persuade him to let me have a go in it! lollol
But, iirc the meriva vxr is the 1600 from the corsa, this is a 2.0 :thumb:
marcgte
08-11-13, 02:48 PM
Good read up
joff-turbo-nova
24-11-13, 09:08 PM
Right quick update from the weekend ...
Started getting the new front dampers and springs (Meriva VXR spec dampers with Cobra -30mm springs)....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2704_zps631a2a07.jpg
One fully built up..
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2705_zpse3c50352.jpg
And the other...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2706_zps46461360.jpg
Then got the car jacked up at the rear and put the Meriva VXR spec rear dampers with the Cobra springs....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2707_zpsff707b82.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2711_zps8e972d3d.jpg
Couldn't find the original rubber spring mats so dug out some poly ones surplus from the nova build. They may be a bit think which could lift the rear end 5mm or so, we'll see when the springs has settled.
Then got the new front damper units installed ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2712_zpsf9fd5523.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2713_zps549b9fb6.jpg
And finally plumbed and wired in the Revotec adjustable thermostatic switch in the top hose, which comes in at 91 degrees and cuts out at about 84 degrees. This may be slightly too low , so will keep monitoring it and may adjust it up slightly....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2715_zps9bc2ba2a.jpg
Next jobs are rebuilding the front bumper and HID's in the headlights.
Joff
nova_stee
24-11-13, 09:22 PM
Has the front end all been painted now?
Shocks and springs look good, arches need a wash tho...llol
joff-turbo-nova
25-11-13, 11:25 AM
Has the front end all been painted now?
Yes, but still needs flattening & polishing so will wait till that's done before taking some pics.
Joff
joff-turbo-nova
08-12-13, 09:54 PM
Quick update,
Been busy getting two cars through MOT's (a lot of work when its an abused V reg Astra!), splicing the video footage together for the schools Christmas production (lots of 1am's I don't want to repeat) and enduring a 54 hour blackout / brownout, so not much time spent on the meriva.
I did spot one of these Travel Assistant boxes on ebay and thought it was worth a punt .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/Travel1_zps6ce2a598.jpg
The front drinks holder was not working (which I was aware of ) and I didn't really like the sliver trim as it didn't really go with the VXR carbon look trims at the tops of the doors or around the dash, so I fixed the spring in the drinks hold and this works nicely now and started pulling the rest apart ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2729_zpsc258ada8.jpg
I has some spare carbon wrap in the garage so dug that out and started playing....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2730_zpsf87993c5.jpg
And all back together ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2731_zps6a704bd9.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2732_zps9a0e6760.jpg
Just need to mount the two mounting trims on the back of the middle seat and its ready to go - will need to install the rear seats first !! I have a few days off before Christmas so will work on the Meriva more then.
Joff
joff-turbo-nova
22-02-14, 10:31 PM
Hi again,
Apologies for the lack of updates over the last month or so, I've been down with a virus type thing that has left me feeling dizzy and tired all the time. Very annoying when you have shed loads of jobs to be getting on with.
Well over the last few weeks I started feeling a bit better and have been able to start cracking on with a few jobs.
First was getting the front bumper built back up - headlamp washer jets....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2824_zps6ab6bcbe.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2825_zpse1189c7d.jpg
I deliberately fitted them the wrong way round just to give myself more work! The should point outwards towards the edges of the bumper! I rectified this after a trial fit.
The grille was then trimmed and stuck in , due to the intercooler things are very tight behind the bumper...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2826_zpsa227d281.jpg
I then put the fog lights in - I had some Lamin-x headlamp light tint film floating around so used this on them....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2829_zps462a7b50.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2828_zps3464ce8c.jpg
Here's the bumper fully rebuilt ready to fit - found out the standard bumper towing eye covers don't fit the VXR bumper . I ordered one from Vauxhall without checking the price and nearly fell over on collection when they said with trade discount it was £17 +VAT !!!! For a bit of round plastic !!
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2872_zps61030e79.jpg
Got the headlights back in , I used some more of the Lamin-x film on these too , not too sure of the results , the jury is out on these at the moment...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2874_zpsc92149ee.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2875_zpsac99d2a1.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2879_zps72f418c8.jpg
No grille in yet as the bonnet needs redoing as the paint has reacted on one side. Its going back next week for a few things to be sorted (like a flat and polish!)
Continued....
joff-turbo-nova
22-02-14, 10:31 PM
Also found that the headlight washers keep popping the main windscreen washer fuses which isn't good - not sure why, so I have gone to plan B, installing some relays and a timer circuit.
So one project box...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2880_zps1621c941.jpg
Some relays and a timer circuit...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2881_zps151b0094.jpg
And all mounted up....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2882_zps297681eb.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2883_zpsf9d6714f.jpg
Need a feed from the main beam (yellow) earth (brown) live (red) washer pump (black/green) and the feed to the headlamp washer pump (black/red) 5 wires and it should be sorted!
Sorted the travel assist brackets today - fairly straightforward ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2898_zpsfdd330b6.jpg
And the box sits like this....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2899_zpsbaa26a37.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2900_zpsf02f8032.jpg
Also got one of the rear doors built up, electric window motor installed, new woofer & tweeter inserted and waxoyled....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2892_zpsc93e1a9d.jpg
Found that my VXR door cards for some reason have a hole for the manual window winder - strange as Meriva VXR's all came with electric windows from the factory ??
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2902_zps53a4e7bd.jpg
I've used a rubber grommet in the hole at the moment but have sourced some proper blanking grommets that look like this...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/blank_zps627779bd.jpg
Also put on the Focal decals from the speaker grilles which I am not using ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2903_zpsec57dc7d.jpg
Well that's it up to date now, just need to work on the nearside front door and put in the handle, speakers and waxoyl and its ready to back to the sprayshop sometime next week.
Pip pip
Joff
nova_niek
23-02-14, 12:33 PM
Again, nice work sir Joff!:thumb:
Looking great now its all painted, maybe a lil bit more tinted headlights?
joff-turbo-nova
23-02-14, 07:58 PM
Next up was the front passenger door.
New focal speakers top and bottom and waxoyled inside...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2904_zps806b0cd3.jpg
The Focal tweeters sit in the same mounting points as the OE tweeters which is really handy....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2905_zpsb0638639.jpg
Next job was to wire in the rear offside electric window. Handily the nearside already had the wiring in so I only needed to sort one side. Sourced from a scrap yard last year the sill wiring looms which had the extra wires for rear electric windows.. where to start!!
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2914_zps1faab27e.jpg
Needed to add the extra wires into the existing plugs under the kickpanel ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2915a_zpsa4efc2f2.jpg
And all back together and now working as GM didn't intend !
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2916_zpsf3894077.jpg
Noticed the plastic sliders in the mechanism seemed a bit brittle - may invest in a repair kit just in case!!
Cheers
Joff
Vlietje
24-02-14, 05:19 AM
Good job mate!!
joff-turbo-nova
03-03-14, 09:16 PM
Weekend update....
Noticed that the fuel pump was quite loud from inside the car so set about putting some extra sound proofing in . Before....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2917_zpsdd6943b8.jpg
And after with a few layers of sound proofing down ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2918_zps94116a66.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2919_zpsc197c1fd.jpg
Next up were the VXR rear seats. Middle seat first....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2928_zps4a2fe3f8.jpg
Then the offside one....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2929_zps59682794.jpg
And then the nearside....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2931_zpsa483d259.jpg
With the seats installed and the extra sound proofing the fuel pump is hardly audible , which is good.
I then cracked on with lots of wiring jobs, like putting the mic in for the bluetooth headunit, wiring in the feed for the TomTom satnav which lives in the dash, and the biggest job was to extend the wiring for the display unit, which I have relocated further down the dash, under the ash tray. Not sure what wires do what, so I extended all 20 of them !! .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2937_zpsbc1d3f28.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2938_zps7f7fd5fa.jpg
I'm doing a few trips this week so put the grille back on....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2941_zpsee55b2ae.jpg
With the new VXP badges, made out of real carbon fibre with the P in gold rather than red...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2942_zpsaa569290.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2945_zpsbddce7a9.jpg
The Merv is now off at the exhaust spot to get a new middle pipe and back box made up in 2.5" pipe with twin rectangular pipes, similar to the irmscher back box that's on.
Also noticed that there is a thrumming vibrating coming from the front offside. It only happens on acceleration and after research it could be either
a) wheel balance issue
b) steering geometry issue
c) driveshaft or CV related issue.
Having had the wheels balanced again today and the geometry checked and adjusted, its still doing the vibrating, so I need to source a replacement driveshaft to see if that solves the problem.
Cheers
Joff
Rear seats are very nice.
joff-turbo-nova
07-03-14, 03:58 PM
Just picked up the car from the stainless exhaust spot. We now have a 2.5" system with an Irmscher style tailpipe......
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2946a_zps93c3c98e.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2947b_zps7062476a.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2948a_zps37e0a309.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2949a_zpsb094a785.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2950a_zpsa8117cbc.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2951a_zps4c813186.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2952b_zps020639c6.jpg
Done by a chap called Len from PipeTech based in Hunmanby, nr Scarborough...
PIPETECH <LINK> (http://www.pipetech1.co.uk)
Really happy with the work and sounds LOADS better now !
Joff
joff-turbo-nova
09-03-14, 10:57 PM
Weekend update,
Cleaned up the replacement driveshaft....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2953_zpsc6850ff1.jpg
Started stripping the front hub.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2954_zps930175e4.jpg
Pulled the old driveshaft and replaced the whole unit with the new one. Rebuilt and took for a test run. I'm pleased to confirm the grumbling noise was completely gone, which was the green light to give it some beans...
http://www.youtube.com/watch?v=kH2AoCaxINw&feature=youtu.be
Got the centre console back in and finished off some wiring jobs, wired in the new fan override switch. Lives in the panel just below the handbrake...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2955_zpsafea0307.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2956_zps0c45efa8.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2964_zpse664f074.jpg
Started building up the dash, new position for the LCD display....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2967_zps0743f2b1.jpg
And piano black trim.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2972_zps2cd9e937.jpg
Which matches the steering wheel....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2975_zps2f399063.jpg
And here's the exhaust from a standing angle....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2968_zps2afc957f.jpg
Team Heko came to play at my house ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2969_zps20a46ca2.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2970_zpsb66f3109.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2971_zpsc745757a.jpg
Need to get on with flocking the A pillar trims next week.
Cheers
Joff
nova_niek
10-03-14, 06:59 PM
Weekend update....
And after with a few layers of sound proofing down ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2918_zps94116a66.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2919_zpsc197c1fd.jpg
Excellent update Joff.
What soundproofing material did you use? What's it like price wise if you don't mind me asking?
Cheers,
Niek
joff-turbo-nova
16-03-14, 07:53 PM
Excellent update Joff.
What soundproofing material did you use? What's it like price wise if you don't mind me asking?
Cheers,
Niek
Niek,
I used the cheap method ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/flashing_zps97e063e3.jpg
10m x 150mm is £15 in B&Q
Seems to work as good as the "soundproofing" stuff that costs stupid amounts !
Joff
joff-turbo-nova
16-03-14, 08:24 PM
Weekend update.....
I flocked the A pillar trims last week so got on with putting them back in and installing all the dials and hooking up the feeds from the engine...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2986_zpsc8073628.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2988_zpsd7ed5bf5.jpg
Even did a video of them when you switch on....
https://www.youtube.com/watch?v=QtvPibxw7NA&feature=youtu.be
Today I got out the new snowfoam stuff I got a few weeks back. I tried this ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2990_zps1a944ffb.jpg
In this...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2991_zps500891ea.jpg
Which resulted in this ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_2992_zps520b7bf7.jpg
(Complete with cat investigating!)
Once dry I put on the rear badge as well...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3017a_zps07427190.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3018_zps06754025.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3019_zpsaa098d14.jpg
We seem to have cutting out problem when there is less than 1/4 of a tank and you go round a corner quick. I bypassed the in tank filter when I changed the pump , but I think the filter must have a swirl pot in it too. I have ordered some more flexible nylon pipe and clips and will reinstate the filter next weekend .
Apart from a small oil leak coming from the rear main crank seal (I think) everything seems to be running well at the moment. If the seal doesn't bed in and stop leaking, its going to be a gearbox off job to get as it's behind the flywheel. A job for Easter Week when I have some time off I think.
Joff
Jeff16v
16-03-14, 09:57 PM
Cracking job Joff, is that the same cat that survived the airbag incident.:)
millworm
16-03-14, 10:09 PM
Really loving this build, just read though it all and it's the best meriva I've ever seen :thumb:
Vlietje
17-03-14, 06:52 AM
Joffmeister you are a legend!!!
Maybe a stupid question: Isn't the lambda too "slow" at that rear (ok, I see it's middle, but not front eg. on C20XE)? Or the Z20LET have 2 lambdas?
joff-turbo-nova
17-03-14, 10:15 AM
Why the fan button?
Mainly due to the fact that I have bypassed the BCM for the aircon. The aircon button on the dash now directly engages (via a relay) the magnetic clutch on the a/c compressor, however when the rad gets warm, the BCM can't call the fan to turn on, hence the fan override button - to be used mainly when sitting in traffic or going slow when its quite warm weather (one lives in hope!)
Also handy if you are generally sitting in traffic and you want to cool the engine down a bit.
Joff
joff-turbo-nova
17-03-14, 10:17 AM
Maybe a stupid question: Isn't the lambda too "slow" at that rear (ok, I see it's middle, but not front eg. on C20XE)? Or the Z20LET have 2 lambdas?
They have two, one one the precat decat pipe, just after the turbo and one further down just after the cat. The first one does most of the work with the air/fuel, the second just measures what's coming out after the cat for emission purposes.
Joff
joff-turbo-nova
17-03-14, 10:20 AM
Cracking job Joff, is that the same cat that survived the airbag incident.:)
Sadly no, we lost her in January when she was knocked down just up the lane. She survived, but had major internal injuries, so we had her put to sleep. She now lives under some plants in the front bed where she liked to sleep in the summer. :cry:
Joff
dgbnova#1
17-03-14, 10:54 AM
Well just read the lot start to finish some great work there some things I was in aware of (the earth clamp mods and oil restrictor bit) so there a great help just love this gona have some funny looks of people when you pull away in that great work
Mainly due to the fact that I have bypassed the BCM for the aircon. The aircon button on the dash now directly engages (via a relay) the magnetic clutch on the a/c compressor, however when the rad gets warm, the BCM can't call the fan to turn on, hence the fan override button - to be used mainly when sitting in traffic or going slow when its quite warm weather (one lives in hope!)
Also handy if you are generally sitting in traffic and you want to cool the engine down a bit.
Joff
Ah, very well thought though.
Jeff16v
17-03-14, 07:52 PM
Sadly no, we lost her in January when she was knocked down just up the lane. She survived, but had major internal injuries, so we had her put to sleep. She now lives under some plants in the front bed where she liked to sleep in the summer. :cry:
Joff
shame mate.
nova_niek
18-03-14, 09:45 PM
Niek,
I used the cheap method ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/flashing_zps97e063e3.jpg
10m x 150mm is £15 in B&Q
Seems to work as good as the "soundproofing" stuff that costs stupid amounts !
Joff
Cheers!
Really love this, would love this as a family wip!
joff-turbo-nova
22-03-14, 07:04 PM
Quick update...
Got the headlamp washer system working to my satisfaction....
https://www.youtube.com/watch?v=tbEwd29eYCo&feature=youtu.be
Needed to take out the under screen trim and fire wall to get to the necessary wiring which took a while.
Joff
Vlietje
22-03-14, 08:20 PM
Didn't even doubt you got that sorted as for a man that built a radio facia in a sunvisor, this is peanuts! Good job Joff!!
Not to critise another excellent thread but that passenger side looks a lot more powerful than the drivers
joff-turbo-nova
23-03-14, 08:53 PM
Not to critise another excellent thread but that passenger side looks a lot more powerful than the drivers
If anything it should be the other way round as the drivers side jet is nearest the pump - I think its just the angle the camera was at , which caught the spray in the light from the headlight. In real life they spray about the same.
Sunday update...
Got two of the back seats out and cracked open the fuel tank. Reinstated the intank filter to see if this stops the cutting out under low fuel levels. I also directed the return fuel pipe into the swirl pot too....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3036_zps167fb400.jpg
Once all back together I replaced the poly spring seats with the normal rubber ones...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3039_zpsab189a1d.jpg
Also sourced some 5mm spacers for the rear....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3040_zps045b966c.jpg
Can't really see they make that much difference at the rear....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3043_zps2003759b.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3044_zps319abc1b.jpg
Also put these on which I sourced last year, the jury is out , not so sure....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3047_zps2224fc8d.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3048_zps5cc60352.jpg
Also needed to fix my lighting in the garage. I'm running T12 tubes, which were last made in 2011, so having to replace the guts so I can run T8 tubes ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3042_zps817c1d96.jpg
This is where the new ballast lives..
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3041_zpsdb6edd98.jpg
Once all wired up ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3046_zps0ad77c81.jpg
I've done 2 units at the weekend, I have 3 more to do, once another T12 tube fails another unit will get done and so on until I'm fully T8 converted.
Joff
millworm
23-03-14, 09:24 PM
Looking good as always mate, not a massive fan of the stickers though
joff-turbo-nova
30-03-14, 09:49 PM
Looking good as always mate, not a massive fan of the stickers though
As mentioned the jury is out on these - I'll have them on for next week then decide at the weekend, however I'm currently leaning towards removing them.
Weekend update...
Not much happened as we were aware visiting relatives, however this box arrived in the week....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3107_zpsb456a50f.jpg
Which had these parts in it .....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3109_zps70f24e0d.jpg
Along with this nice jack....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3110_zps84412d20.jpg
Put it together and had a look how high it went....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3111_zpsb196478a.jpg
And here it is right down....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3113_zps5751d4b1.jpg
Ready for action.....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3114_zpsc1c0b6e0.jpg
And my old one ready to be dispatched to a farm in Whitby shortly !
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3108_zps73080879.jpg
Joff
I thought it must be something like camera trickery
We're you happy with the nova mirror covers you won on eBay ?
scottmasterton
07-04-14, 01:29 AM
any updates?
joff-turbo-nova
07-04-14, 10:35 PM
Quick update,
I've decided. The decals in the rear window are going.
I also ordered a new crank oil seal today from Vauxhall in preparation for the gearbox and flywheel removal. The oil leak is still present so will need to change the crank seal over Easter, weather permitting. It's using about 1/2 a litre per 250 miles, whilst although not drastic, needs fixing as I can't run around with it constantly dripping, plus the underside of the car is getting quite moist in places!
Also picked this up last week off ebay - a Corsa VXR dbilas flowmaster - it has the inlet and outlet in just the right places to make it mate up to the pipes in situ, just need to make a bracket up.
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3348_zps2af8d037.jpg
I've already cleaned the K&N filter inside and re-oiled it with K&N filter oil.
On a side note, the wife's Meriva is now at 107k. She does about 18k pa due to her job so next year we will need to change her car. The Meriva's have been breeding...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3296_zps45301ae7.jpg
(We now have 5 3/4 Vauxhall's at our house now!)
Picked this up from a chap in Scarborough at the weekend...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3301_zps4c4566d8.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3305_zps98825f33.jpg
It's a cat C and needs some front end work, but generally a nice and tidy car and has done about 47k....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/Meriva3_zps82278b39.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/Meriva2_zps961aa245.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/Meriva1_zpsd1a4689a.jpg
Believe it or not the aircon system was still gassed and holding pressure!
I stripped the front end down to make it more presentable...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3303_zps52013b17.jpg
Engine bed has a dint, but the chassis legs are straight. Just needs a wing, bonnet, bumper (and bar) and headlamps. I already have the bumper from my Meriva and the rest of the parts I will round up over the coming months.
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3304_zpsf1f812bb.jpg
A collection of bent parts...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3306_zps56c4a9d8.jpg
Joff
dgbnova#1
07-04-14, 11:10 PM
Looks like your starting your own group there VMOC possibly
love the vxr bit not sure of it's purpose but I'm still on catchup on newer engines
CorsaBBoomer
08-04-14, 08:09 AM
Love this! The gf here has a Meh-riva with the 1.3... Wished we could do some engine-swaps too :cry:
joff-turbo-nova
09-04-14, 12:19 AM
Looks like your starting your own group there VMOC possibly
Note the user info here
<
PMG !
lollollollol
dgbnova#1
09-04-14, 01:07 AM
PMG think mine was better tbh lol plus yours is the only "performance" one I've seen
lots of owners out there
ps I'm of to spec savers after missing that
joff-turbo-nova
13-04-14, 09:30 PM
Quick update...
Had a Bank 1 lambda sensor error code pop up this week. As it was the original lambda that was 12 years old, I can't really moan too much. Sourced a replacement and got it fitted today, access was a little limited but we got there in the end.
I also noticed a very small coolant leak from one of the water pipes to the turbo so nipped up the banjo so hopefully will sort that.
Whilst the induction was stripped out the way I fitted the new Corsa VXR flowmaster , which seems to fit quite snugly ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3423_zps57e58f08.jpg
I fettled one of the brackets to fit a empty bolt hole which now holds it nice and solid...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3424_zps96c4f7c2.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3425_zps8085d56f.jpg
Also played with the satnav, which now shows this picture on boot up and shut down...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3426_zpsc5fb96f6.jpg
Looking to get a bespoke mat for the dials as well, notice the difference?
http://i2.photobucket.com/albums/y15/joff-turbo-nova/MEriva-VXP_zpsbd6682f8.jpg
Also got a new crankshaft oil seal ready for next weekends little job...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3430_zps4b52eb32.jpg
That's about it for now.
Joff
nova_niek
14-04-14, 08:42 AM
Lots of stuff going on here. The dBilas flawmaster, is that some sort of resonance chamber/plenum type thing? Its purpose is somewhat of a mystery to me. Can you please clue us/me up on this Joff?
On another note, I got to discuss your flashtape soundproofing solution with some chaps off the Dutch Lupo forum. The reckon that, on hot days, it could get rather smelly inside your car. What is your experience?
joff-turbo-nova
14-04-14, 10:14 AM
Lots of stuff going on here. The dBilas flawmaster, is that some sort of resonance chamber/plenum type thing? Its purpose is somewhat of a mystery to me. Can you please clue us/me up on this Joff?
On another note, I got to discuss your flashtape soundproofing solution with some chaps off the Dutch Lupo forum. The reckon that, on hot days, it could get rather smelly inside your car. What is your experience?
The flowmaster has a K&N ribbed filter in the middle of it and has minimal disruption to the airflow . Works similar to a 1.9 CDTI airbox conversion - only that doesn't fit in a meriva !
Used the same stuff in the Nova, applied it in 2006 and we've had some hot summers since (a couple!!) and there doesn't seem to be any "odours" coming from the floor pan.
Joff
joff-turbo-nova
19-04-14, 09:57 PM
Right , got busy with the stripping down of the front end trying to get the gearbox out ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3455_zps1c237116.jpg
Got the battery tray out , a few coolant hoses and various bits of wiring loom - there's the M32 lurking down there...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3461_zpsf1334ece.jpg
Disconnected the suspension and engine mounts and dropped the engine bed out....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3463_zps8ff40353.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3464_zps39cd18e3.jpg
Then with the assistance of my Dad (cheers :thumb::thumb::thumb: )we undid the gearbox mounts and lowered one end , then supported the engine on a support bar ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3465_zps2172a66b.jpg
And removed the gearbox and pulled it out on the new jack with the clutch and flywheel coming out shortly after....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3466_zps659dd59a.jpg
Here's the crank seal - note the oil pooling at the bottom of the seal......
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3467_zps541b0f31.jpg
And here's the new one in - looking exactly like the old one !!!
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3468_zps6e16f3d0.jpg
Seems the seal didn't seat right when I originally installed it and therefore it decided it would leak to tell me it wasn't happy !
So once installed we put the flywheel and clutch back in and manhandled the gearbox into place and put it back on the mounts. Once I had taken off and resealed the upper and lower sumps, the engine bed was next and the front and rear mounts.
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3469_zps72cfa525.jpg
That's about where I am now. Need to sort driveshafts in the morning , suspension, some wiring and plumbing and then put all the fluids back in.
Joff
Awesome work as always Joff, i still love the way you make it look oh so easy lol
nova_niek
22-04-14, 10:57 AM
All in a day's work... except that if I were to perform the above tasks, it'd take me 3 weeks of solid swearing. :d
joff-turbo-nova
22-04-14, 01:24 PM
All in a day's work... except that if I were to perform the above tasks, it'd take me 3 weeks of solid swearing. :d
There were still a few "choice" words floating around trying to get the gearbox to sit right on the input shaft splines!
Joff
PMG think mine was better tbh lol plus yours is the only "performance" one I've seen
lots of owners out there
ps I'm of to spec savers after missing that
There's a guy that comes in my work with a VXR, noticed it the first time cause the front tyres had the threads showing..
HE told me he'd done a track day the day before.
Good lad i thought, Since then i've had him in for turbo/exhaust gaskets as he's uprated the turbo. Insigna VXR discs, asked about polly bushes..
Guys a legend.
joff-turbo-nova
22-04-14, 05:55 PM
Insigna VXR discs
Wow , they will be fairly hefty - they are about 321mm aren't they??
Joff
I think so, upgraded turbo with a full engine rebuild, coiloved and such. Hes a big track day man so....
Southie
22-04-14, 09:46 PM
So Joff is this a scary quick car now? Faster than your Nova???
It looks great btw, a family wolf in sheeps clothing :)
joff-turbo-nova
22-04-14, 09:59 PM
So Joff is this a scary quick car now? Faster than your Nova???
It looks great btw, a family wolf in sheeps clothing :)
No, not as fast as the nova, the kerb weight is something like 1600kg so dulls the out and out performance when compared to a nova, however that said, it is quick, just a bit more refined than the balls out C20LET I have in the Nova.
I left a Cooper S for dead off a roundabout recently (that has 185 bhp and 1200 kg kerb weight). Engine still feels quite tight and although its got a remap on it , it could do with a bespoke map being applied live on a rolling road. I'm down for a rolling road dyno session with VXRO at RS Tuning in Leeds, which I have heard good things about. I will see how the engine is performing , and if it has some issues I will consult Specky about a session.
Joff
joff-turbo-nova
26-04-14, 11:27 PM
Quick update,
After speaking to a number of contacts, I have been looking for a trusted bodyshop to do look at sorting the paint on the Meriva. The previous shop did a rather shoddy job , and the business has now gone bust and the premises repossessed (no surprise there) .
The new bodyshop specialises in the older classic cars from the 40's and 50's (names which escape me) and I have seen some of their work which seems very good.
I left the car with them on Tuesday and I popped in today to see how they were getting on. They seem to have cracked on and made some progress in rectifying the issues....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3478_zpsbcb1eeb9.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3479_zpsc5d4cf72.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3480_zpsaa1bb1ca.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3481_zpsdcd9b612.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3482_zpsb186edcf.jpg
This was also parked up - a blast from the 80's ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3483_zps24257465.jpg
A long term project apparently.
Mine should be sorted by early next week fingers crossed.
Joff
joff, when do you reckon you'll stop having to take it apart & get thrashing down the roads scaring children & old people in it?
or is this your forth bridge project?
ps. any approaches from TV mag yet?
joff-turbo-nova
27-04-14, 07:57 PM
joff, when do you reckon you'll stop having to take it apart & get thrashing down the roads scaring children & old people in it?
or is this your forth bridge project?
ps. any approaches from TV mag yet?
There are 2 issues at the moment - paint which is being sorted and the driveshaft issue, which is still causing problems, especially into quick left hand bends .
The issue is that the Z20LEH imtermediate idle shaft (which bolts to the back of the block) is 38mm longer than the Meriva VXR / Corsa VXR version which uses the Z16LET engine. This means that the outer driveshaft sits 38mm further out, meaning the inner CV joint is at near full compression for most of the time, and when you start leaning into a left hander, it starts complaining as it reaches max compression. This isn't good for either the drivetrain or the engine/gearbox mounts.
However a chap I found, who specialises in grass track creations, is getting an outer driveshaft made up for me, 38mm shorter. This should cure the last of the issues, now the oil leak is fixed.
Fortunatley the change of driveshaft is quite straightforward, especially as you don't need to drain the gearbox of oil to do it !
I've had a couple of conversations with Dan , editor for TV, he seems interested in getting a feature, however I don't think this will be a front cover as it looks a bit too standard.
Joff
joff-turbo-nova
04-05-14, 09:51 PM
Weekend update....
Got busy replacing the VXR parts with non-VXR or VXP alternatives.
First up was the gear knob , this was removed ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3522_zps9463d7f7.jpg
And replaced with with this....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3527_zps7eaf7b9b.jpg
The dial mats arrive last week and look excellent quality ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3509_zpsa2245b65.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3510_zpsa28ee02f.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3513_zps266d3048.jpg
So started stripping the clocks down ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3539_zps0179a658.jpg
And installed the new mats ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3547_zps982c478c.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3550_zps0bffe7de.jpg
I've gone for the uncluttered look without the kph ring or markers at 30mph and 70 mph.
Also got busy with the steering wheel - removed this ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/AstraVXR_zps83590baf.jpg
And made a few changes like this...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3474_zps7e0a6dbc.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3477_zpse41d369a.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3475_zps477d252b.jpg
Then on with the colour...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/IMG_3492_zps489bca84.jpg
A coat of lacquer and installed in the car...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3514_zps0ab0193b.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3515_zps0ae75ab5.jpg
Continued...
joff-turbo-nova
04-05-14, 09:53 PM
These arrived last week - Omega Elite 17" alloys - originally purchased for the wifes new Meriva, but I'm thinking they might look better on mine !!
They are a bit rough and need a fair bit of TLC....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3504_zps27b9b3df.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3505_zpsedc7d727.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3507_zpsdc59316a.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3506_zpsf64a01a0.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3508_zpsb000aea5.jpg
Got busy cleaning under the bonnet , from this ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3540_zps2f32647c.jpg
To this ....
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3541_zps4efdbc37.jpg
To this (thanks to Keif for the idea!) ...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3542_zps59508466.jpg
New back number plate went on...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3543_zps8a3000c0.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3544_zps9d8aeae6.jpg
Put a new 2nd lamda on as I was getting some error codes from the old one - whilst it was on axle stands I cleaned up and finished off the alloys...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3552_zpsb5a9c212.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3553_zpse20a1c1a.jpg
Again thanks to Keif, I source some VAG bolt caps and modded one to fit the wheel locking nut...
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3554_zps82fb4ae1.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3556_zps617fc101.jpg
Continued..
joff-turbo-nova
04-05-14, 09:53 PM
And just as the light was fading I took a couple of pics once the front bumper was back on, the spray shop have made a real good job of fixing things ..
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3557_zpsf2fcaa26.jpg
http://i2.photobucket.com/albums/y15/joff-turbo-nova/joff-turbo-nova001/IMG_3560_zpse8e18723.jpg
Joff
Kev Turbo
05-05-14, 07:43 AM
I must admit there have been times whilst reading your updates I have questioned modifying a Meriva to this extent but those last two pictures look great - Top Job.
dgbnova#1
05-05-14, 08:15 AM
Love it my fav non nova build on here and such detail awsome car
On the Omega rims will look good.
THe clocks.... Did you get them made some where from scratch? Or just recovered?
joff-turbo-nova
06-05-14, 06:20 PM
On the Omega rims will look good.
THe clocks.... Did you get them made some where from scratch? Or just recovered?
Made from scratch by this chap - highly recommended - will basically make what you want ....
http://www.xtuners.com/shop/
They are based in Bulgaria, but don't let that put you off - top notch work and fits first time with no "tweaking"
Joff
Southie
06-05-14, 07:45 PM
A credit to you Joff it looks brilliant.
joff-turbo-nova
06-05-14, 10:00 PM
A credit to you Joff it looks brilliant.
I haven't given it a proper detail yet - I will need to do so in the next few weeks as its coming to PVS and Billing this year! The nova is taking a back seat in 2014 as there are a number of jobs that need sorting - mainly the EPAS, which has failed for some reason - I have a spare column, just not the time to change it over !
Joff
Made from scratch by this chap - highly recommended - will basically make what you want ....
http://www.xtuners.com/shop/
They are based in Bulgaria, but don't let that put you off - top notch work and fits first time with no "tweaking"
Joff
Hhhmmm i wonder if they could make me something up.... Cheers dude.
love what you done with it. one thing id think about changing is the headlamps to the smoked xenon ones found on some later merivas.
also keep the gsi wheels they work well
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