Project Freeze My Ass Off (rear Poly Bush's Astra G)

[evocarlos]

I used spacers to move the aircon pump forward. About 1 inch if I recall right. I will measure it up for you. That way and with a little careful bending the pipework and the manifold will just fit. Moving the pump forward will mean you need another length aux belt. I'll check that for you too.
You'll need longer bolts for the pump too because of the spacers

thanks will have a look what i have for the job tomorrow the other thing i was looking at was astra 1.7td a/c pipes
the bolts are not a problem
im now looking at using the usa bracket to make the extra idler pulley

 

[z22se-fan]

Are you using the usa bracket to make a courtenay style idler pulley? Or will u use it as tensioner?

 

[evocarlos]

Are you using the usa bracket to make a courtenay style idler pulley? Or will u use it as tensioner?

make a cs style idler from the usa bracket
well its already the right shape just need to drill a hole in it a and tap it out to m8 then fit a tensioner wheel as an idler
found a pic on the interwebs
basically like that but with ac pump


not sure what this one is or where its from but i think this style will do it

 

[z22se-fan]

Excellent! Will let you know those measurements tonight

 

[z22se-fan]

Excellent! Will let you know those measurements tonight

Belt is 5pk1538 and the spacers from the aircon are 3,6cm. With the spacers the aircon pump sits right behind the oem radiator (thicker rad won't fit). I also skimmed off 1,2mm off the idler pulley bracket for good clearance of the belt.

 

[evocarlos]

Belt is 5pk1538 and the spacers from the aircon are 3,6cm. With the spacers the aircon pump sits right behind the oem radiator (thicker rad won't fit). I also skimmed off 1,2mm off the idler pulley bracket for good clearance of the belt.

thanks for that
so are you running the standard usa bracket and cobolt alternator ??

 

[z22se-fan]

thanks for that
so are you running the standard usa bracket and cobolt alternator ??

Nope, cs bracket and original bosch 100A alternator. I believe @JohnnyN has the original lsj/cobalt setup

 

[evocarlos]

Nope, cs bracket and original bosch 100A alternator. I believe @JohnnyN has the original lsj/cobalt setup

ok well im well under way now the a/c pump is out of the way going to make the idler later

heres the work so far

PCV blocked off with gasket maker


then i had an idea to save my self £10+ shipping on the CS alignment bungs for the manifold
stainless steel collars OD = 10mm ID= 6.5mm seamed right what with the z22se block being 6mm pins


armed with a 10mm drill bit and the manifold i started on the 2 outer most holes and the top middle
meaning it would be aligned with these 3 bolts fitted i did not drill all the way thru


left the collar proud so it would recess itself when clamped down


here it is after a bolt had been down on it


z20let fuel rail #2 was gratis so fitted the injectors to the z22se fuel rail


inlet on


and the new wiring plugs for the injectors fitted

 

[pottsey]

great work carl ,saved a few quid on making the alignment bungs up yourself too ,whats the pcv I didn't block mine off like that

 

[evocarlos]

great work carl ,saved a few quid on making the alignment bungs up yourself too ,whats the pcv I didn't block mine off like that

PCV positive crankcase ventilation port it puts some of the oil vapor from the rocker cover back into the inlet but being as i'm using z20net steel gasket it dont line up so it got blocked off i will now rely on the rocker cover pipe to inlet for this process

 

[vx-chris]

So in theory then the pipe which goes from the cam cover to the intake pipe isn't needed if it has that pcv (or whatever you call it) as that's doing the same job?

Coming along nicely now stop watching star gate and get it finished lol

 

[z22se-fan]

There you go!
Might be easier to put the charger on without the fuel rail...
Have you decided where you will place the ecu?

 

[z22se-fan]

So in theory then the pipe which goes from the cam cover to the intake pipe isn't needed if it has that pcv (or whatever you call it) as that's doing the same job

No, the other way around

 

[Matt]

Nice update Carl

 

[evocarlos]

So in theory then the pipe which goes from the cam cover to the intake pipe isn't needed if it has that pcv (or whatever you call it) as that's doing the same job?
Coming along nicely now stop watching star gate and get it finished lol

you still need the main one from the cam cover as said
but stargate is just getting good

There you go!
Might be easier to put the charger on without the fuel rail...
Have you decided where you will place the ecu?

it comes out easy enough with the rail bolted down bit of a twist job
i'm thinking z20let style and leave the battery tray in place for 2 sports batteries running in parallel
""see pic below""

Nice update Carl

thanks matt i was not thinking straight yesterday ive not had any cheap red bull for 3 days lol must borrow moms car and go stock up


a wiring nightmare

 

[pottsey]

if your putting 2 batterys and ecu in original battery place is that not gonna compromise room for the air filter,or is the pic decieving

 

[Matt]

The wiring would be the thing I'd not like to do the most.

 

[pottsey]

The wiring would be the thing I'd not like to do the most.

me neither that's why steve @cavaddict done mine

 

[evocarlos]

if your putting 2 batterys and ecu in original battery place is that not gonna compromise room for the air filter,or is the pic decieving

its a deceiving pic from the images i saw of your build theres enough room to fit the battery tray and a proper car battery
i dont have that luxury so going to have to improvise but im trying to keep it OEM looking theres plenty of room for a filter and the small type batteries you had
can you link me to there site so i can get dimensions

The wiring would be the thing I'd not like to do the most.

me neither that's why steve @cavaddict done mine

the wiring is simples its just a case of moving the ecu and extending the wires that are already there and you have seen i did the climate control mod so this lot is easy for me just trying to keep it all tidy

 

[pottsey]

http://www.tayna.co.uk/ODYSSEY-PC680MJ-P3108.html