C20XE in nova...

[novarobbo]

basically i want to know what is needed, what work is needed (seam welded ect..) parts? (conversion kit) any bashing things out with a hammer ect..

ive searched for these things but the search button dont seem to be working for me! :o

[Ste L]

engine, brakes, mount kit (vavlers.com) 22 spiline gte or td nova shafts, mk cav 1600 inner cv's and seam welded engine bay

[DIY*VALVER84]

and patience if anything goes wrong...i followed instructions to a tee and ive still got it wrong somewhere or another lol. do not even look at a haynes manual cuz you might as well read the instructions of a fckin cornflakes box...and yes a big hammer is a help,4 your mate who trys to tell you what to do and he dont got a clue,lol!!!

[loggyboy]

Think ive covered everything:

XE Quick Guide

Items:

Donor 16v engine
Uprated brakes (256mm recommended minimum/standard)
Multipoint Injection spec fuel tank, pump and lines
Custom drivers side engine mount (or lower existing chassis mount by around 1.5 inch and use the metal bracket from a mk2 cav.)
10mm Spacer for rear gearbox mount.
Uprated Rubber engine mounts recommended
High spec? SR, GTE, GSi etc rad recommended (1.0 will not suit)
Driveshafts - 22 spline items (most GTE, TDs and some GSIs)
Retain the Nova outer CVs (will mate with any nova hubs)
Early 1.6 Cav/Astra inner CVs (16SH engine number, MK2 Cav around 1988 model)
Custom exhaust (either adjust XE downpipe to mate with Nova system or adjust nova system to mate with XE downpipe)

Work/adjustments:

Seam/stitch weld engine bay.
Adjust Drivers side chassis leg to allow for alternator pulley.
Grind off the lug on the bottom on the g/box which fouls the tie bar.
Shorten the front gearbox to chassis mount bolt till its flush with the nut (or you can insert the bolt the other way, but this makes it awkward if you need to change the mount for any reason)
Adjust clutch cable exit angle (down and towards Passenger side.)
Some inlet manifolds have a lug that needs gringing off so it doesnt foul with heater pipe.
Trim drivers side heater matrix pipe to as small as pos (whilst still allowing enough to fit the rubber pipe back on)
Use nova gear linkage but spin the plastic pivot 180 degrees to extend it enough to meet the XE gearboxes selector
Wiring:
Perm power, accessory power (must be live when cranking), fuel pump, rev and temp gauge.
Plumbing:
Top rad hose will need tweaking to connect to XE thermostat housing but you can mix n match most pipes from XE and original Nova to suit.