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View Full Version : *HOW TO* Fit a 2.0 8v/16v into a Nova



Lee
19-09-07, 07:39 PM
The nova 20XE conversion is outlined below. You need to consider all the points in the list, but the 20XE and 20SEH engines do bolt into the nova pretty simply. I found this guide on Valvers.com, but they failed to mention stich welding the engine bay (strengthening all welds in the engine bay by welding in 1 -2 inch sections along all joins)

Another thing not mentioned is a brake upgrade which is essential so please see guide to upgrading your brakes.

This is written purely as a guide, not an instruction manual. I take no responsibility for serious injury or death if said conversion is not completed to a safe standard!
Good Luck!

1. Fuel
If you nova is a carb model, you need to install injection fuel lines, or at least think about how you are going to deal with the fueling of the 20XE. The fueling system for the 20XE requires two lines from the petrol tank, one supply, and one return. 1ltr novas do not have a return fuel line, and therefore you either need to braize a fitting into the petrol tank as a return, or you need to install a petrol tank with a return line in it.

The fuel pressure required for an injection engine is much higher than that required for a carb model, and the fuel hose used in the carb models should not be used to carry the high pressure fuel required for the injectors. As a get around, if you don't have time to install the injection fuel lines right down the car, you can mount the fuel pump in the engine bay. Now, as the pump sucks the petrol from the tank, this is not at pressure. Only the section after the pump, and before the regulator is high pressure. Bear in mind, this is NOT the ideal way of doing things as the pump is designed to be as close to the tank as possible. The return line can always be left as the std petrol line.

When using a carb tank, there is no swirl pot in the tank. The swirl pot holds a reserve of fuel if you like, and when you corner hard this reserve of fuel is still able to be put through the pump, even though the petrol in the tank is all being shoved out of the way of the supply line opening because of the cornering G.

So a swirl pot in a fuel injection tank is the best way forward.
The GTE / GSi / SRi fuel pumps are fine for the 20XE, as is of course a 20XE fuel pump. The Spi 1.4i (single injector) pump cannot flow enough fuel at a high enough pressure for the 20XE though, so you will need to replace this pump if it is the model you have.

2. Chassis
The engine conforms to Vauxhalls family 2 layout, and all the Nova mounting brackets will actually fit the 20XE engine and the F16/F20 gearbox. However, there are a few exceptions. The TD engine mounts are different because the lump is an isuzi made diesel, and the 1ltr front offside engine mount is different too.

The front offside mount must be changed from standard so that the engine sits approx 1-1.5" down from it's std position. This sits the engine straight, and also enables you to shut the bonnet without risk of the engine hitting the bonnet. To do this, you can either use the standard nova mount, but cut the chassis bracket off, and re-weld it onto the chassis leg 1-1.5" further down the leg, OR purchase a 2.0 fitting fit from a specialist, which will also include the spacers for the rear gearbox mount (as follows below).

The other mount that isn't right is the rear gearbox to chassis mount. This holds the gear linkage, etc. You need to use a Nova item, and you can keep the nova gear linkage but flip the plastic universal joint around to give the nova linkage a longer reach.
However, the differential casing of the F20 and F16 are different to the F10/F13, etc small block gearboxes. You need to put spacers between the rear gearbox mount (as mentioned above), and the gearbox differential so that the engine/gearbox is not twisted in the engine bay.

On the 20XE inlet manifold there may be a lug on the part that comes around where the inlet runners meet, this comes into contact with the drivers side heater matrix hose, and needs to be ground off. As well as that, whether you have that lug or not, you still need to cut down the drivers side heater matrix hose by at least 10mm, but take off as much as you can to give that hose more room to bend down under the inlet manifold.

The inlet manifold also gets in the way of the clutch cable exit from the bulkhead. Insert an iron bar into the clutch hole in the bulkhead and make the hole point towards the front passenger side of the engine bay, towards the floor. This will let the clutch cable be free.
Otherwise the clutch cable is pushed about by the inlet manifold, and it ends up snapping the clutch cable.

The alternator pulley hits the chassis leg of the nova right by the drivers side suspension turret. This means you need to alter the chassis leg to avoid the alternator pulley. This mod needs to take the chassis leg in so that it's inline with the suspension turret to miss the alternator. You also need to alter the crank pulley. You must run the single-V alternator pulley, and not the poly-V one that came on later engines. You need to take off the outer V on the crank pulley, which is used for the PAS + Aircon pump belt on cavs, etc. You can machine it off, or grind it down with an angle grinder or similar. Make sure you try and keep it fairly balanced though, as it sits right on the crank.

The engine also moves about quite a bit, especially on standard rubber mounts, so make sure that there is plenty of room for it to move. Alternatively, purchace some solid motorsport mounts.

3. Suspension
Running standard uprated shocks + springs is not great, but it seems to work well enough to get you started. Seriously think about getting some proper rated bits for the conversion though, it makes a lot of difference. Ideally you want 300lb rated springs on the front to support the extra weight.

The Anti-Roll bar hits the 2ltr tubular exhaust manifold. This can be got around in two ways. You can either remove the anti roll bar all together, and run without one, or you can modify the tie bar brackets to lower them on the front cross member. With the added weight at the front of the car with the 20XE engine in, running without the ARB isn't as daft as it sounds. It helps in a way because you tend to get more understeer with the heavier engine anyway. Most people prefer the handling with the ARB removed. It's wise to use a strut brace with the 2ltr conversion IMO.

4. Driveshafts
Two options here. Either..

Fit 22 spline driveshafts (from Nova Gsi, some GTe and most TD's) mated to MK2 Cavalier 1600 inner CV joints.

OR

Fit custom 2.0 shafts with conversion hubs allowing you to run 2.0 outer CV joints.

5. Wiring
Wiring is easy, the motronic looms are whole looms in their own right. All you need to link between the nova and the motronic loom is a Permanent live ( large red ), Switched live ( Black ),an earth ( Brown ), and a feed to the Fuel Pump (Red/Blue) for the engine to start. The rest of the wires from the Nova's original loom will connect up to the alternator / starter / oil presure / water temp sensors ect.

Notes
Use a nova clutch cable
Use an Astra / Cav accelerator cable. Mine needed adjusting on the accelerator pedal to give full throttle.

Checklist:
Alternator - chassis clearance + bottom pulley to chassis
Front offside engine mount bracket
Gearbox diff spacing
Gearbox linkage
Gearbox bottom lug
Anti-roll bar + tie bar lowering
Driveshafts
Heater matrix driver side needs to be cut down + lug on inlet manifold
Clutch bulkhead exit needs to be bent over towards passenger side

Riggy
15-02-08, 11:21 PM
and this is a guide from practical performance car

http://img.photobucket.com/albums/v13/riggy4/general%20pics/Artical20page201.jpg

http://img.photobucket.com/albums/v13/riggy4/general%20pics/Artical20page202.jpg

save the pics and you can see them a bit bigger if you struggle to see them here

Sloth
15-02-08, 11:49 PM
a bit more info on the wiring side would be good, as thats what most people struggle with! with photos if poss! :)

Adam
16-02-08, 12:45 AM
Wiring Guide-Thanks To Paul

Right, hope I haven't forgotten any wires here, otherwise be pretty useless lol

This is for a DISTRIBUTOR C20XE, the dispacks are identical apart from they have on more plug for the dipack unit.

Maybe make this a sticky seeing as its a common topic/problem?

http://img.photobucket.com/albums/v14/lashednova/XEWIRING.jpg

ALL WIRES/PLUGS ARE BLACK UNLESS STATED OTHERWISE

WIRES FROM THE DIAGRAM:

1- This is the wire which goes to the fuel pump, the fuel pump live. It is blue with a red trace, as illustrated.

2- This is the Fuel Pump Relay, they have a few wire going into them and only one coming out which is item 1 on the diagram

3- This is the big plug which goes into the ECU, It has a silver clip which you push down to secure the plug into the ECU, these can be tricky to master the first few times you do them!

4- These are the dash signal plugs, out of these two you will use the following wires:

BLUE- Temperature Display for Dash, to BLUE on Nova dials
BROWN with BLUE trace- ECU warning light, colour for colour on injection Nova dials/Digidash, unless it was a carb model, in which case, use the choke light as a ECU light, which is BROWN with YELLOW trace
GREEN- Tachometer (rev counter) goes to GREEN on nova dials



5- This is the gromet bung which is where the wires will go trhough to the inside of the car through a 60mm hole you drill in the bulkhead. TIP: you need to cut the tape holding the bung in place and slide it down towards the ECU plug for a better fitment

6- This is the Permanent live for the ECU, it is a red wire, in a black sheafing, it should have a ring terminal on the end, it goes to the positive side of the battery

7- this is the three pin plug for the Lambda Sensor, the line going through indicates that the plug should be around here somewhere.

8- This is the plug for the Air Flow Meter (Commonly known as AFM) Think it has 7 pins?

9- This is the coolant temperature wire, it is blue and simply pushes onto the nipple next to the Coolant Temperature Switch.

10- This is a blue plug with 2 pins, it goes to the coolant temperature switch sensor (commonly known as CTS Sensor). This is located at the front of the block by the top rad hose

11- This is the Crank Position Sensor,, it goes in the lower front face of the block, it is held in by one bolt. The line further up the loom towards the ECU indicates a plug for it

12- This Plug goes into the Hall Sensor on top of the distributor, it has 3 pins, you really cant miss this one!

13- This plug goes into the coil.

14- This is the switched live (a.k.a. Ignition Live). This should go to a 12V igtion live source, this will turn the ECU on and off with the ignition.

15- This is a 5 pin (I think?) plug which connects to the back of the block loom. It will be down by the speedo cable drive somewhere. (The loom from the back of the block should include, knock sensor, ICV etc)

16- These are earth, 3 separate wires, one on cambelt end, 2 on gearbox side, they should be earthed to the fuel rail.

17- This is the plug for the Fuel Tank Vent Valve, it is a 2 pin plug. It goes at the very end of the block, usually bolted to the bottom stud of the inlet manifold (gearbox end)

18- This is a plug for the Throttle Position Sensor (TPS) It is located on the cambelt side of the throttle body.

Other Wires

You need an earth that goes from the gearbox to the chassis.

You also need to connect the starter motor live to the +ve side of the battery

From the Nova Engine Loom (found by brake fluid reservoir), you also need to connect the black with red trace to same colour on the engine loom at back for the starter motor. Again from the Nova loom, you need the blue with white trace as the remote wire for alternator, to the same colour on the XE loom. Again for the Oil pressure, you need to connect the blue with yellow trace and blue with green trace to the XE Oil Pressure sender, this is found down behind the Oil Filter.

Hope this of some help to some of you,

Paul :thumb:

djshaggeh
08-03-08, 01:20 AM
there is also another guide
http://www.corsa-novatuning.nl/uk/PartsA.htm

16v_nova_16v
07-04-08, 03:04 PM
so where does the nova loom go and ecu because there are nothin on here on where they go or if u get rid and wat wires are for digi dash do u need from loom? i have a c20xe nova thats been bodged lol so need to correct it all but need help

Novaload_Nick
10-04-08, 07:20 PM
I rearly need a wireing guide for a 2.0 8v.. the wireing in my nova is disgracefull!! :( any 1 that could help me please??

Lee
02-05-08, 11:26 PM
Wiring is pretty much the same as above pal.


Something else to note, on very early pre-cat 20XE's you may come across an engine harness with some colour discrepancies. In this case you wont find a black switched live wire, instead youll find a black with a yellow trace. ALSO, the blue/red wire does NOT run to the fuel pump, its the BLUE wire you need to run to the pump.

Confusing as feck, i was tearing my hair out thisafternoon!

nova258
06-05-08, 11:04 PM
the gude is very good it helps me so much , i nead to know what size are the stabilizer spacers ? and it is alloy or iron? 10x

Paul
13-06-08, 02:04 PM
4- These are the dash signal plugs, out of these two you will use the following wires:

BLUE- Temperature Display for Dash, to BLUE on Nova dials
BROWN with BLUE trace- ECU warning light, colour for colour on injection Nova dials/Digidash, unless it was a carb model, in which case, use the choke light as a ECU light, which is BROWN with YELLOW trace
GREEN- Tachometer (rev counter) goes to GREEN on nova dials

FUEL PUMP- This is the thick wire which goes to the fuel pump, the fuel pump live. It is blue with a red trace, as illustrated.

http://img.photobucket.com/albums/v14/lashednova/xejibberish.jpg

coombsey
14-08-08, 06:48 PM
what colour plug for idle control valve brown or black

Paul
07-09-08, 11:38 PM
Drew this for a post in Technical, so thought I may aswell chuck it in this thread too:

http://img.photobucket.com/albums/v14/lashednova/20plumbingguide.jpg

jord77
08-09-08, 11:45 AM
Above very helpfull

thanks just what i needed :)

RSTChris
17-09-08, 08:54 PM
Any pics of the inner wing alternator clearance mod?

AlexW
18-09-08, 12:39 PM
Have a look in some project threads, trackdaynova springs to mind too.

RSTChris
18-09-08, 07:14 PM
Im only on dial up mate and it would take a few week or so lol

Would anyone be soo kind....

AlexW
18-09-08, 07:32 PM
Im only on dial up mate and it would take a few week or so lol

Would anyone be soo kind....

Here ya go:
http://www.turbo-nutters.co.uk/images/switch_nova/nc0174.jpg

Hope Trackdaynova dont mind.

RSTChris
18-09-08, 07:45 PM
Thanks for that mate but is there any pics of one Bashed in? I feel cutting it like that takes some strength out

Adam
18-09-08, 08:11 PM
You box it back in, its probably stronger than standard when its boxed in

trackdaynova
18-09-08, 08:23 PM
Of course I don't mind AW06 :) thats what I take the pics for... to help others out...

this is what it looks like once finished Chris, as Adam said, alot stronger than previous...

http://www.turbo-nutters.co.uk/images/switch_nova/nc0176.jpg

RSTChris
18-09-08, 08:42 PM
Sweet, thanks for that :) V nice!

Nice looking shell also

Jon_nova1
21-08-09, 10:20 PM
so do the 2litre wires go to the digi-dash? or is it the original nova loom thats used for that?

also the flipping the gear linkage, which way? upside down or left to right? (i want it ready for when the engine arrives)

doesn't matter, got the dash figured :D

nova-taken
31-10-09, 01:20 AM
excellent guide, this shal come in very handy indeed in the coming weeks.

Cheers

Grey
14-04-10, 06:13 PM
Question .....

The 1.2 spi loom im wondering what do.... ive pulled the tiny ecu which is bolted near passenger footwell behind dash the two plugs i pull of ecu do i just leave them as they are or wire into something else??? i have my c20xe loom wich from what i know of is simple but just those 2 plugs are bothering me :mad:. advise please?:thumb:

Damo
14-04-10, 10:34 PM
you dont need to connect them to anything mate just leave them or cut the spi loom out.

Grey
15-04-10, 08:17 AM
you dont need to connect them to anything mate just leave them or cut the spi loom out.

nice one thanks alot!

david sloan
07-07-10, 02:01 PM
can any 1 tell me what internal fuel pump a need for my mpi tank to run a 2.0 8v seh, its the tank that has 6 bolts in the top for the pump and the 1 return hole on the front.............. or if anyone has one for sale send me a personal message.

Sloth
07-07-10, 03:43 PM
you need an astra mk3 2.0 or 1.8 mpi pump

chrisnovaturbo
07-07-10, 06:42 PM
can any 1 tell me what internal fuel pump a need for my mpi tank to run a 2.0 8v seh, its the tank that has 6 bolts in the top for the pump and the 1 return hole on the front.............. or if anyone has one for sale send me a personal message.

pm'd

eddgsiturbo
13-07-10, 07:42 PM
does any1 have a lil diagram of were the water hoses go for a let engine? obviously the other pipes are the same but a let has the water feed in and out so what do you join them to. cheers :thumb:

let_nova
13-07-10, 07:45 PM
http://www.pngclub.com/forum/showthread.php?t=109836&highlight=diagram

shrtwrec20
27-07-10, 10:45 PM
Nice article mate. You say the driverside mount needs lowering, but is this only for 1.0 shells or would I need to do this with my 1.2 spi shell?
Thanks

Sloth
28-07-10, 11:52 AM
all shells need it lowering by 1.5 inches.

shrtwrec20
28-07-10, 11:55 AM
Anyone? :)

shrtwrec20
28-07-10, 01:07 PM
all shells need it lowering by 1.5 inches.
Thanks mate

Paul
05-09-10, 12:45 PM
http://www.pngclub.com/forum/showpost.php?p=821701&postcount=4

Fow16v
24-09-10, 09:45 PM
done a search but cant find anything, im going big block with c18xe soon and im wanting to use cav or similar hubs machined and pressed in nova bearings, this i can sort. The bit i cant remember is which shafts i need can i use cav/calibra etc do i need to shorten them and make a new circlip groove?

Sloth
25-09-10, 12:35 AM
iirc you need conversion shafts, its corsas you re groove em on. id look for gte shafts with cav 1.6 innners, fine for that conversion mate

dave1010
28-03-11, 01:57 PM
I am in the process of the conversion but useing bike carbs got the manifold and carbs had my dizzy converted (off the 1.2) got a good spark but cant get it to run. I did have it running until the starter broke changed that now but waont fire up any ideas guys?????

shed-on-wheels
13-04-11, 08:31 PM
earth wire?

Vinny-NOVA
22-04-11, 08:03 PM
hey Lee, been reading your thread on the 2.0 REDTOP CONVERSION. I have a 1.0 litre carb nova, the fuel lines, tank braize, fuel pump and swirl pot sounds a biggy. What sort of cost would it be for these changes?

Iain
23-04-11, 10:42 AM
Wouldn't have thought that lot would cost over £100 (new tank, second hand fuel pump, make up some new fuel lines)

poultergeist
26-09-11, 03:05 PM
Anyone on here happy to carry out above modifications for £?

Also,any pics of the inner wing work?

robert_novaj611
07-04-13, 09:45 PM
i am bulding an xe can i chop th spi loom out like the pi injector wires and do i need the map sensor aswell just want to doo away with the wires i dont need

Timmy
09-02-15, 06:17 PM
I found this on mig though it would help people dunno if its worth being made a sticky
http://www.migweb.co.uk/forums/engines-transmission/481102-c20xe-coolant-hoses.html

sorry im at work and don't have my photo bucket to hand someone ok to host the image at the bottom of the page

McFall1984
10-01-20, 08:40 PM
Bit of a thread hop. I’ve a 2ltr 8v here that I’m thinking of running on twin 40 webers

is there a guide on that?
ie what’s needed and not in the 8v loom

millworm
10-01-20, 08:51 PM
Bit of a thread hop. I’ve a 2ltr 8v here that I’m thinking of running on twin 40 webers

is there a guide on that?
ie what’s needed and not in the 8v loom

You'd pretty much bin the 8v loom and use a mk2 cav dizzy and loom for ignition only or join the 21st century and use a mappable ignition like nodiz or MBE and run a wasted spark setup in either 2 or 3d

McFall1984
10-01-20, 09:03 PM
Don’t see a point in myself buying a mappable ECU. If I can just get it to run an be reliable enough it will do me just fine

i have all here to run standard now room. New distributor, arm, coil an leads
bjt thought came into the head of running twin 40 webers

millworm
10-01-20, 09:17 PM
They're not actually as expensive as you'd think, if you go webers then your standard dizzy will be no good with the cav setup but will work with the mappable ignition. To be honest unless you're slapping a cam in I'd stay standard, also 45s are probably a better shout on a 2.0

IxilnuM
16-02-24, 04:19 PM
Have you considered reaching out to users in the forum who have undergone similar 2.0 REDTOP CONVERSION modifications for insights and cost estimates based on their experiences?