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Author Corsa GSi c16xe rebuild!
mar_cus
Member

Registered: 29th Apr 09
Location: Congleton, Cheshire
User status: Offline
14th Jan 10 at 21:12   View User's Profile U2U Member Reply With Quote

I started a thread a while back but i can't find it, but i've been keeping up to date on corsa-c.co.uk as i have a corsa c as well you see.

So put in a new post with all my progress from start to where i am now

When i bought it i had the following spec:

C16XE
4-2-1 Race Manifold
Gloss Black Morrettes/Roof
Full GSi Bodykit
GSi Fans wheels in gloss black with red pin strip
Astra 2L Front Brake Upgrade
Full Leather Calibra Interior
DVD Headunit
Lowers 60mm all round on G-Max Shocks

and looked like...





firstly i had to fix the speedo!





Problem was, no cable!





and was then sourcing for a new engine and stumbled across this...



unfortunately plans didn't go as i thought and i never bought it!

Few more bits and bobs to put it on track, fit a new inner CV boot and a pretensioner to the drivers seat!









a nice piccy of it next to the c



Then i had a period where i just gave up on it due to uni and work and just lack of money, i sold the morettes to fund general life, which i regret now Coming up to winter 2009 and i return to this..



So with loads of motivation and a student loan which i could spend, i took underway to rebuild the whole car into a road/track slag



Basically, i've had time to strip back parts of the loom, take off the fuel lines and detach most things in site! Just a little more to do, i'm stuck at getting one of the driveshafts out, just mm's off. So annoying, cba to take the whole hub off but looks like i will have to at this rate! Other than that, just abit of the loom to take off from behind like on the alternator and a few earthing wires.







Got the engine out, pictures should do the talking!





Jet washed all the crap off the engine and took off the gearbox, clutch, flywheel.

Found out that the standard flywheel on this c16xe weighs TOO much, its a pot type and ideally i need a flat type or just a generally lighter one! all thou, so that's something 2nd hand I'm going to keep my eye out for!

Took my time polishing the throttle body as the weather was a bit bad and i haven't got my engine stand yet so the garage is messy - hopefully picking it up tomorrow.





Engine stand arrived and built



Engine up on the stand, bit of a b1tch to get on, there in the end





Cams out, and head bolts out got to take the Crank wheel off so that i can take off the plastic cover out which covers the cam belt etc...then i can lift the head straight off and start on the sump and hopefully have the crank out to be sent off for grinding and then fit new bearings!



Got the head off and started work on the block, pistons out first:







Abit of a clean up for the pistons



Then honed the cylinders, came out a treat!









Then a bit of smooth black hammerite to smarten up to the block!






Collected my xmas cash, and decided to add to it and buy some new bits and bobs In the end i spent a bit just on parts to get the engine completed!



Cleaned up the gearbox reading for painting and also two pics of the rocker and the sump.
Waiting on big ends and piston rings, then i can start putting this back together!





Painted the rocker cover gloss black...



Next update involved...

Painted Gearbox
Finished painting Rocker cover
Cleaned and rebuilt head
Rebuilt the block and fixed on must of the tensioners/water pump/idler pulleys/starter motor/power steering pump
Stripped all the back seats out (just need to take out the seat belts a back door cards now)
Fixed up the injector loom and alternator/starter/battery loom
Wax oiled all rust patches in the engine bay













Then finally picked up my big ends....but they are the wrong ones



On the other hand, picked up a gasket set for the head and an oil filter, just because i was passing by!



Sorted out the ball joints with a helping hand and undersealed front arches completely!





i picked up, piston rings, correct big ends, sump gasket and i got some new rocker cover bolts to suit the gloss black also ordered my conrod bolts from vx.






...and the correct big ends!!





Picked up my new piston rings, and fitted them







Picked up a set of abs sensors off here, cheers bryant



Got some Red dot 20 Groove Discs, vented! from *White GSi* - cheers boss



Got my little sticker for the boot lid too
Got my abs sensors
Got my conrod bolts
Picking up rear strut brace/inlet manifold at the weekend

Conrod bolts...





BOOM! Another mega deal, picked up a pair of willians 3 point harnesses from ebay at a steal



So yeah, thats it for now, will keep this thread updated aswel as else where


Cheers!
DannyE2010
Member

Registered: 1st Jan 10
Location: Wales/Caerphilly
User status: Offline
15th Jan 10 at 17:50   View User's Profile U2U Member Reply With Quote

bet alot of money been put into rebuilding this lol, just wondering aw much have u spent rebuilding it cause im lookin at gettin a gsi engine into my sport an id like to rebuild it befoure it being put in.another quicky what paint do u use wen painting a engine ??cheers
Linch
Member

Registered: 4th May 06
Location: Whickham, Tyne and Wear
User status: Offline
15th Jan 10 at 17:54   View User's Profile U2U Member Reply With Quote

A dont mean to sound a chod here or anything...but when you honed the bores are they not meant to have hatched lines like this? or is it just you cant see that in your picture?



apart from that looks spot on

[Edited on 15-01-2010 by Linch]
flybikeslee
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Registered: 2nd Jan 07
Location: Liverpool
User status: Offline
15th Jan 10 at 17:56   View User's Profile U2U Member Reply With Quote

nice progress
mar_cus
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Registered: 29th Apr 09
Location: Congleton, Cheshire
User status: Offline
15th Jan 10 at 18:07   View User's Profile U2U Member Reply With Quote

Its my crap phone camera mate! Lol! They are hatched
Linch
Member

Registered: 4th May 06
Location: Whickham, Tyne and Wear
User status: Offline
15th Jan 10 at 18:09   View User's Profile U2U Member Reply With Quote

Oh right good stuff looks well mate any plans for performance parts?
mar_cus
Member

Registered: 29th Apr 09
Location: Congleton, Cheshire
User status: Offline
15th Jan 10 at 18:27   View User's Profile U2U Member Reply With Quote

quote:
Originally posted by Linch
Oh right good stuff looks well mate any plans for performance parts?


Haha, yeah and the flash on my cam sort of distorted things too!

Performance wise, i'm picking up a mantzel powerbox tomorrow, other than that nothing much until i get it run in.

But for the future...

Pocket the pistons for cams and have the head fully done, p&p new valves etc.
*whitegsi*
USER UNDER INVESTIGATION - DO NOT TRADE

Registered: 3rd Aug 09
User status: Offline
15th Jan 10 at 18:28   View User's Profile U2U Member Reply With Quote

brakes are been collected monday pal

looks smart shouldnt have sold morettes though
dalejones
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Registered: 9th Dec 08
Location: Swansea, Wales
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16th Jan 10 at 10:56   View User's Profile U2U Member Reply With Quote

looks crackin! fair play mate! i wouldnt have a clue lol good effort!
edd1.0
Member

Registered: 17th Sep 08
Location: kettering
User status: Offline
16th Jan 10 at 12:21   View User's Profile U2U Member Reply With Quote

lookong good although it looks lower then 60mm
mar_cus
Member

Registered: 29th Apr 09
Location: Congleton, Cheshire
User status: Offline
17th Jan 10 at 13:21   View User's Profile U2U Member Reply With Quote

quote:
Originally posted by *whitegsi*
brakes are been collected monday pal

looks smart shouldnt have sold morettes though


Awesome mate, nice one! looking forward to putting them on
I regret selling the morrettes but i'm going to get some depos i think!

Cheers for the comments guys
mar_cus
Member

Registered: 29th Apr 09
Location: Congleton, Cheshire
User status: Offline
17th Jan 10 at 13:33   View User's Profile U2U Member Reply With Quote

Small update (pics to follow):

Pistons back in and torqued up along with all the mains. Sump back on and torqued up...and just about to put the head back on
mar_cus
Member

Registered: 29th Apr 09
Location: Congleton, Cheshire
User status: Offline
17th Jan 10 at 22:49   View User's Profile U2U Member Reply With Quote

Abit more work went into it over the weekend. Managed to get the pistons back in, sump on and the head on with the cams and alternator. Just need to time it up and almost there!

Some pics...









BUT, i'm so pissed off because i had a major accident and sheared one of the bolts from the cam bearings which hold the cams onto the head, and i don't have any tools to sort it out, i'm actually gutted. So i've contacted philips and i think he can sort it for me and also whilst i'm up that way... port and polish
So a delay, but....gonna be worth it! The bucket seats will just have to wait now because i won't have enough money due to getting my head sorted, so putting it all back together, i have to take it all back off. And to top it off, i'm gonna have to get a new head gasket and head bolts!

benji123
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Registered: 12th Jan 10
Location: lancaster
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17th Jan 10 at 22:56   View User's Profile U2U Member Reply With Quote

love it mate, should be a monster once its done =]
mar_cus
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Registered: 29th Apr 09
Location: Congleton, Cheshire
User status: Offline
17th Jan 10 at 23:19   View User's Profile U2U Member Reply With Quote

quote:
Originally posted by benji123
love it mate, should be a monster once its done =]


Cheers mate, and yeah! I hope its a monster - just gotta sort all these little bits n bobs! its annoying atm but it'll get there!
AlexW
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Registered: 25th Oct 08
Location: Essex
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17th Jan 10 at 23:22   View User's Profile U2U Member Reply With Quote

Shearing the cam bolts is so easy to do, IIRC there ment to be done up to about 4NM.

Looking good so far though. Makes me want to buy a stand and rebuild my baby valver.
mar_cus
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Registered: 29th Apr 09
Location: Congleton, Cheshire
User status: Offline
17th Jan 10 at 23:26   View User's Profile U2U Member Reply With Quote

quote:
Originally posted by AW06
Shearing the cam bolts is so easy to do, IIRC there ment to be done up to about 4NM.

Looking good so far though. Makes me want to buy a stand and rebuild my baby valver.


Yeah they are 8NM, and thats what i did it to and it just went pop....think it was just a weak bolt
Ollie_B
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Registered: 1st Jun 08
Location: North Wales/Wirral
User status: Offline
17th Jan 10 at 23:29   View User's Profile U2U Member Reply With Quote

Nice work , i need to get an engine crane and i'm rebuilding my 1.6
AlexW
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Registered: 25th Oct 08
Location: Essex
User status: Offline
17th Jan 10 at 23:36   View User's Profile U2U Member Reply With Quote

Ahh i was close, couldnt remember if it was 4 or 8. I was warned that they sometimes just snap without warning. Shouldnt be TOO hard to sort though.
mar_cus
Member

Registered: 29th Apr 09
Location: Congleton, Cheshire
User status: Offline
17th Jan 10 at 23:53   View User's Profile U2U Member Reply With Quote

quote:
Originally posted by AW06
Ahh i was close, couldnt remember if it was 4 or 8. I was warned that they sometimes just snap without warning. Shouldnt be TOO hard to sort though.


Yeah, well its not that its hard to sort its just im at uni during the week and only get weekends to work on it, so its just a delay for me! Oh well, its a good excuse to get a port n polish!!
mar_cus
Member

Registered: 29th Apr 09
Location: Congleton, Cheshire
User status: Offline
19th Jan 10 at 20:04   View User's Profile U2U Member Reply With Quote

Little update on a few things i've ordered...

Received my brakes from white gsi! (sound lad)
Awaiting my new radiator and 3 point harness's
Just won a brand new engine mount on ebay for 20 so thats sorted now
Ordered a set of flatblade wipers

All i need to do now is get this sheared bolt out of my head, and have it ported and polished. Get a battery and fit it all! Although, due to my mate needing his engine crane back i might be fitting the block and gearbox this weekend to the car, need to tidy the loom up first though!
Ollie_B
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Registered: 1st Jun 08
Location: North Wales/Wirral
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19th Jan 10 at 20:15   View User's Profile U2U Member Reply With Quote

Is there a bearing that goes between the cam and the clamp?, like the big ends and main bearings? Just wondering
mar_cus
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Registered: 29th Apr 09
Location: Congleton, Cheshire
User status: Offline
19th Jan 10 at 20:19   View User's Profile U2U Member Reply With Quote

quote:
Originally posted by Ollie_B
Is there a bearing that goes between the cam and the clamp?, like the big ends and main bearings? Just wondering


No mate, well not on mine lol...if you look at them they act as a bearing themselves, they have a little groove where oil flows to lube the camshaft when its moving
Ollie_B
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Registered: 1st Jun 08
Location: North Wales/Wirral
User status: Offline
19th Jan 10 at 20:21   View User's Profile U2U Member Reply With Quote

Ahh good cheers mate, just getting a list together of what i need to order
mar_cus
Member

Registered: 29th Apr 09
Location: Congleton, Cheshire
User status: Offline
20th Jan 10 at 18:00   View User's Profile U2U Member Reply With Quote

Just been noted that my my harness's have arrived, will add a picture when my brother sends me one! Also had my flat blades delivered to!

So all i need now is my new radiator which was dispatched this morning and my engine mount! Oh, and sort the head lol!

I'm going to looking into fitting the harness's but not sure on how to do it? Anybody got ideas? I was looking into getting the eyes which you can clip them onto? Thoughts??

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