Engine Swap in 11 hours

Maverick

Regular Member
Been a little busy over the past few months, but it all came together on the 8th October.

Firstly, I bought a brand New Lotus Europa Z20 LER engine and a new VXR turbo, along with a rough Turbo cabby donor car for the management and gearbox.

But as you can see I ended up pretty much replacing everything lol!
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The Airtec Intercooler was replaced with a Courtenay intercooler as I didn't want to lose the A/C.

A bit of restoration work for the cooling fan housing, before it was fitted to a brand new radiator and A/C condenser.

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Starting to build the engine up on the stand.

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Lotus/Mk5 Astra Engine loom removed and Z20LET loom fitted.

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Decided to buy new solid water pipes s well.

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VXR Injectors Fitted

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Complete front Z20 LET body harness, cleaned, re-done in new fabric tape, new clips and checked ready to go in.

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Then at 9.30am on the 8th October, we started the conversion!

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2.2 Out and ready for Chris to come and collect.

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LER in place and starting to connect everything up.

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We then programmed the clocks, central display, and collant module to Z20 LET, changed the chassis number in the ECU to my car's chassis number. We also changed the security code in the ECU to my cars original security code.

Turned the key for the first time, and...............


Then at 8.40pm, I drove the car home!!

He is how she looked, once we had finished.

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A few little bits I need to do, like shorten a few of the header tank silicon water hoses etc, fit an exhaust heat shield, but more importantly, get hold of the LOTUS spark plug cover.

V5 is now at the DVLA to have it's new cc logged, and also its new engine number. The nice thing is, that as this engine was from Lotus Europa production, it has a Lotus engine number and not a Vauxhall engine number!!!

Also fitted a Cobra pre-cat pipe, and 200 cell sports cat along with a Milltek cat back system.

Drives perfectly well, with the only fault being a failed turbo water feed pipe, which I didn't replace when I did the conversion.

Silly mistake, but all rectified now with a new pipe.

So 11 hours and 10 minutes!

As you will have seen, Chris Smith now has my 2.2 for his van with all ancillaries and a Zafira F23 with the lower 4.17 final drive.
 

corsaZ22se

Senior Member
not bad time.
takes me around 16 hours to do a corsa c > z22se swap but there's more to do.
taking for ever for dvla to sort logo book this time. :(
 
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