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Author Combo van project: 1.7 D to 1.5 TD
Dougie_SRi
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Registered: 27th Jun 05
Location: Bristol
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4th Oct 10 at 15:39   View User's Profile U2U Member Reply With Quote

Hi all,

I've owned loads of Vauxhalls, but strangely never a Corsa. This is close enough I reckon though. I need a daily driver to chuck tools and random car parts in and decided to go for a Combo over an Astravan as I think the load area is better for taking engines/gearboxes.

I picked this up locally. It's a 1.7 D Epic with 90k on the clock and six months MoT. The head gasket has gone though so it's a non-runner. That's not a problem though as I have a Nova 1.5 TD engine and box from a Nova to drop in, which will be much better and should hopefully mean cheaper road tax too. It's got a few scratches and dents, but it's totally solid.

I should be fitting the engine this weekend with any luck, but I have a few questions if anyone can help. The engine mount on the Nova engine is different, and the air intake pipework looks runs all the wrong way round but that shouldn't be too hard to sort. The PAS pump and alternator assembly looks like it will all fit right onto the 1.5 though.

Can I just use a Corsa 1.5 TD driver side engine mount?

Are the seats interchangeable with those from Cavaliers/Mk2 and 3 Astras etc?

I need a set of diesel rev counter clocks!

Once that's done I'll put some bigger wheels and brakes on it, and get it cleaned properly. I'm undecided if I'll tweak the engine, they go really well in a Nova, but a Combo must be a fair bit heavier, so we'll see.

Pics:













[Edited on 04-10-2010 by Dougie_SRi]

[Edited on 04-10-2010 by Dougie_SRi]

[Edited on 04-10-2010 by Dougie_SRi]
Gazdaman
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Registered: 30th Aug 07
Location: Leicester
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4th Oct 10 at 16:28   View User's Profile U2U Member Reply With Quote

Good work, the engine's are almost identical and are pretty much a straight swap. I seem to remember you might need to grind a bit off the bellhousing on the gearbox because it hits something, but I can't remember what.

They're really good engines, cracking fuel economy, and the 1.7TD lumps are very tuneable, can get 100bhp out of them without much issue.

I used to get 56mpg out of my 1.5D
AlexW
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Registered: 25th Oct 08
Location: Essex
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4th Oct 10 at 16:43   View User's Profile U2U Member Reply With Quote

I know you got the nova cheaps, but why not source a 1.7 TD engine? rather than hassle with DVLA etc. From what ive seen on PNG its also a easier conversion!

clubberlang
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Registered: 10th Jun 10
Location: Bawdeswell, Norfolk
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4th Oct 10 at 17:01   View User's Profile U2U Member Reply With Quote

Question: Are the seats interchangeable with those from Cavaliers/Mk2 and 3 Astras etc?
Anwser: Yes mate I've got mk3 astra seats in my corsa van.

Goodluck with conversion Dougie,why don't you use that low millage 1.7td
lump you got from u-pull it?
MarkSport
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Registered: 22nd May 09
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4th Oct 10 at 17:22   View User's Profile U2U Member Reply With Quote

another van
Dougie_SRi
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Registered: 27th Jun 05
Location: Bristol
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5th Oct 10 at 08:43   View User's Profile U2U Member Reply With Quote

I think the 1.5 engine and box should go straight in to the Combo, all I'll need is a driver side Corsa 1.5 TD mount. I'm using the 1.5 for ease and cheapness. It's only done 105,000 miles too so should run on forever. Hopefully going to take the engine out the van tonight.
carl roper
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Registered: 17th May 09
Location: Newport Shropshire
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5th Oct 10 at 17:02   View User's Profile U2U Member Reply With Quote

it will just need the drivers side engine mount swapping over you mite also have to put the 1.7 startor/alternator onto the 1.5 if the wiring plugs are different.
i converted from a 1.5td to 1.7td and had to use the 1.5 bits on the 1.7
Dougie_SRi
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Registered: 27th Jun 05
Location: Bristol
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11th Oct 10 at 15:31   View User's Profile U2U Member Reply With Quote





Took both the engines out over the weekend. The Nova loom disappears somewhere up the back of the dash, whereas the Corsa one is much nicer and self-contained. Therefore, I'm going to use the Corsa loom on the Nova engine, but to do so, I'll have to also use the 1.7D fuel pump due to wiring differences. That shouldn't be a problem though as it fits just the same as the 1.5 TD's does.

I'm now waiting for the Vauxhall Parts Dept to tell me if they can source the Corsa TD engine mount part for me, if not I'll have to try and get one second hand.

Next up is to strip all the stuff off the TD, clean it, do the timing belt/filters and fit the ancillaries. I think I'll probably use the Combo gearbox as it's slightly longer

Does anyone know if petrol 7000 rpm rev counter clocks will work OK with a diesel engine? They're much easier to find than diesel ones!
AlexW
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Registered: 25th Oct 08
Location: Essex
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11th Oct 10 at 15:38   View User's Profile U2U Member Reply With Quote

Diesel rev counter works off the alternator so petrol one wont work.
carl roper
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Registered: 17th May 09
Location: Newport Shropshire
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11th Oct 10 at 19:07   View User's Profile U2U Member Reply With Quote

petrol rev counters do work there just extremly unaccurate.

also you dont need to swap diesel pumps. my 1.5td had 1 wire for the pump where as the 1.7td i put in had 3 wires coming from the pump so i just crimped the wire in my loom to the corresponding wire from the 1.7td plug.

if you need any help/info just leave me a pm and i will be more then happy to help
sand-eel
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Registered: 15th Mar 07
Location: carluke/braidwood--IRNBRULAND
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11th Oct 10 at 21:37   View User's Profile U2U Member Reply With Quote

Are the diesel pre-heaters on these electric or hot water heat exchangers?
am4nf
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Registered: 27th Jul 08
Location: South Ayrshire Drives: Corsa Sport
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11th Oct 10 at 23:26   View User's Profile U2U Member Reply With Quote

love combos, mint set of mk3 astra gsi seats for sale btw, shame ur so far
Dougie_SRi
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Registered: 27th Jun 05
Location: Bristol
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18th Oct 10 at 16:29   View User's Profile U2U Member Reply With Quote

How hard is it to get clocks for one of these? The only set I've seen are on eBay for 35.25 plus postage - err, don't think so.
Anyway, the timing belt kit will be here tomorrow and the 1.5 engine mount is due in at the local Vauxhall dealer on Wednesday (it had to be ordered from Opel) so all being well I'm going to do the belt and clean the engine up on Thurs, and fit the Combo gearbox (longer ratios according to the brochures).
Should be able to get the engine in Friday, and have it running on Saturday. I'm not in that much of a rush now as I don't want to tax it until the beginning of November anyway.
Dougie_SRi
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Registered: 27th Jun 05
Location: Bristol
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26th Oct 10 at 08:23   View User's Profile U2U Member Reply With Quote

Had a busy few days over the weekend. Did the timing belt, then fitted the Combo's gearbox. While the engine was out I also did the fuel screw/dimple/white ring mods.





One of the problems I've encountered is that I never took the water pipe housing from the front of the 1.7D, so I can't fit the 3-way pipe. This means some rerouting of water pipework but I'll have to do that anyway as the header tank fouls the air intake. A trip to the plumber's merchant for a few 28mm copper fittings will solve that.

The good news is that it started up no problem and drives fine (just round the block)...



The only thing is, the glow plug light isn't coming on, and I'm not sure they're working (it did start right up from cold though when I went back to in on Sunday). The pic above is of two wiring plugs from the 1.7D loom that aren't used on the 1.5 TD. Anyone know what they're for, and how to test the glow plugs?


All I need to do now is hook the water pipes and exhaust up, and tax it. Picking up some rev counter clocks on Friday and will fit some Cav GSi front seats next week. Got some 195/60x14 Cav SRi steelies and OE wheel trims lined up, 256mm brakes, and with a three-spoke Cav SRi steering wheel.




Here are the wiring plugs, one connects to the car loom at the driver's kick panel. Is the black box just for EGR?

[Edited on 26-10-2010 by Dougie_SRi]
am4nf
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Registered: 27th Jul 08
Location: South Ayrshire Drives: Corsa Sport
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26th Oct 10 at 11:11   View User's Profile U2U Member Reply With Quote

You dougie from TV aye?

Pretty sure I seen the van in TV this month

Any plans to modify the van? or is it just a workhorse?

I know a scrappies with a 1.5td I could enquire about the clocks if you like?
AlexW
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Registered: 25th Oct 08
Location: Essex
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26th Oct 10 at 11:41   View User's Profile U2U Member Reply With Quote

It is the same dougie yes, The nova was also in TV iirc.

If you remove the glowplugs (providing they dont snap!) You can test them like that via jump leads.
Dougie_SRi
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Registered: 27th Jun 05
Location: Bristol
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26th Oct 10 at 13:15   View User's Profile U2U Member Reply With Quote

Aye, tis me. I found a set of clocks on eBay yesterday, so bought them, collecting Friday. If they have a 1.5, I'd be interested in the control box and relays as pictured above? If I can't get the plugs to work, I'll just wire them up to a switch on the dash via a relay!

I'm doing a few bits and pieces to it to make it nicer, but it is mostly going to be a daily driver/workhorse. Will need to get a bleed valve and boost gauge once it's on the road :-)
MarkSport
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Registered: 22nd May 09
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26th Oct 10 at 14:35   View User's Profile U2U Member Reply With Quote

There is one of these exactly the same just abandend on the motorway services near me, same colour with the td engine in.leather seats aswell
brebaz
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Registered: 11th Dec 09
Location: newcastle
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26th Oct 10 at 14:42   View User's Profile U2U Member Reply With Quote

quote:
Originally posted by MarkSport
There is one of these exactly the same just abandend on the motorway services near me, same colour with the td engine in.leather seats aswell


got a trailer
MarkSport
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Registered: 22nd May 09
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26th Oct 10 at 15:32   View User's Profile U2U Member Reply With Quote

I was tempted to ask if i could have it, go to the police and see what they say etc? its been there since july anyway and not moved
brebaz
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Registered: 11th Dec 09
Location: newcastle
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26th Oct 10 at 15:41   View User's Profile U2U Member Reply With Quote

probly got a tramp sleeping in the back of it haha

 
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