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Author My gsi turbo. Massive long overdue picture update!!
thomson
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Registered: 18th Jan 11
Location: scotland
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1st Apr 11 at 21:53   View User's Profile U2U Member Reply With Quote
great progess! awsome work awsell.
dale87
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Registered: 19th Feb 06
Location: West Mids :)
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1st Apr 11 at 23:51   View User's Profile U2U Member Reply With Quote
cheers mate.

its so nice having the engine sat in the bay, lots of little jobs can be done now so expect better updates over the next few weeks lol
Olsrey
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Registered: 13th Jan 07
Location: Bradford   Drives: LET Vectra B
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2nd Apr 11 at 08:09   View User's Profile U2U Member Reply With Quote
The widebelt alt set-up is fine for a lot of people being that close, but a few (me included) ended up having some sparks around corners. But its down to what mounts you're using really.
dale87
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Registered: 19th Feb 06
Location: West Mids :)
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2nd Apr 11 at 22:05   View User's Profile U2U Member Reply With Quote
Olsrey - I'd read the wide belt set-up was hit and miss weather or not the pulley clears the chassis but mine is just too tight for my liking so I'm going to change to the single v set-up which has always been fine on my xe.


Another update. Not got many picures but got quite a few jobs done today. I'll list whats been done then put up the few pics I took.

Jobs done today were,
Fitted clutch cable
Fitted reverse light switch in box
Fitted starter loom
Attached speedo cable
Fitted both heater matrix pipes and expansion tank
Fitted brake servo pipe
Fitted turbo to rad pipe
Modified the 'turbo' inlet cover to fit the corsa

I then mock fitted the rad and intercooler so I could check exactly where to mount the rad so the slim fan will fit.

Few pics















Next on the list are single v alternator and lmf gear linkage, thanks for looking.
dale87
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Registered: 19th Feb 06
Location: West Mids :)
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3rd Apr 11 at 22:55   View User's Profile U2U Member Reply With Quote
Made more progress today


First of all I took the multi-v alternator off ready for when I can pick up a single v type.



Then I set about fixing the rad in its new place along with the cooling fan and intercooler.

First I marked exactly where it needed to sit.




Then I drilled 2 14mm holes for the bottom rad mounts to sit in the crossmember and also cut down the original bottom mount rubbers to about 10mm thick so the rad sits on rubber as from the factory.




Then for the passenger side top rad mount I simply moved the factory bracket over a bit, keeping the rubber mount still.


Now the drivers side was a bit trickier as the rad is sat further forward this side but in the end I managed to retain the factory bracket and rubber still by bolting it behind the headlight




All mounted up solid and piped it up too. Just waiting on my new header tank, cap and fan switch to arrive then I can get some coolant in it






Turbo clearance.



I also fitted my intercooler and 10 inch fan but I only have 1 pic of the fan clearance before I put the bumper on to make sure it all fits.


Bumper on.









Then I fitted the engine loom which I had already cleaned and re-taped when I first got the engine.


Loom not fully fitted yet but cam across this plug which i'm not 100% sure what its for? any ideas?



And how it sits now. (bumper only held on by 2 top screws in the pics)







And a pic I took which I think looks




Thanks for looking
danny90
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Registered: 13th Sep 10
Location: tipton west mids drives: corsa 1.6
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4th Apr 11 at 19:42   View User's Profile U2U Member Reply With Quote
here is some pics i took m8







progress is good m8 not far now from it being started up lol
dale87
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Registered: 19th Feb 06
Location: West Mids :)
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5th Apr 11 at 21:32   View User's Profile U2U Member Reply With Quote
cheers for pics Dan.

Just a little update - my new expansion tank, cap and fan switch arrived today.
dale87
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Registered: 19th Feb 06
Location: West Mids :)
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7th Apr 11 at 20:59   View User's Profile U2U Member Reply With Quote
Only another small update.


Fitted new fan switch in the rad.



Better pics of my rad, fan and intercooler setup. (still got to squeeze an oil cooler in there yet)





And fitted the new coolant bottle



Also spotted this connection on the let loom. any ideas what its for ? has the same colour wires as the other plug im unsure about but this on is down by the gearbox.
danny90
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Registered: 13th Sep 10
Location: tipton west mids drives: corsa 1.6
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7th Apr 11 at 21:09   View User's Profile U2U Member Reply With Quote
good progress its just good to see it coming together now seeing it every day as the car is in the next room from me ha (garage) there loads of progres not enough hours in the day realy lol good work mate
dale87
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Registered: 19th Feb 06
Location: West Mids :)
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8th Apr 11 at 06:12   View User's Profile U2U Member Reply With Quote
cheers Dan.

I've still got a few little jobs to do before im happy and got a few random parts to buy but i should be able to get it fired up soon.
LukesCorsaSXi
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Registered: 2nd Jan 11
Location: Sheffield
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8th Apr 11 at 19:45   View User's Profile U2U Member Reply With Quote
Looking good mate, cant wait too see it finished! Keep us updated
danny90
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Registered: 13th Sep 10
Location: tipton west mids drives: corsa 1.6
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20th Apr 11 at 21:22   View User's Profile U2U Member Reply With Quote
update update update
pagey
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Registered: 30th Nov 04
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20th Apr 11 at 21:58   View User's Profile U2U Member Reply With Quote
Nice work... Thats my old intercooler lol!
dale87
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Registered: 19th Feb 06
Location: West Mids :)
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20th Apr 11 at 22:11   View User's Profile U2U Member Reply With Quote
Yep done a little more to the gsi this week.


I originally was going to fit a manual steering rack but after a bit of thought I decided to keep the gsi power rack and use a 106/saxo pas pump so last week me and Dan went to a scrap yard where I found what I needed in a smashed up 106. I got the pump, bracket and loom with relay all for £30, not bad imo.




I planned to put the pump on the battery tray and put the battery in the boot but on trial fitting the pump was just crap sat on the tray causing the pipes to be tight and just seemed bodged sat there. So I set about cutting the tray out, it's half bolted half welded but got it out in no time.










I then tried the pump and 106 bracket in the bay and after double checking everything fitted as it should and cutting the bracket to clear things, this was the final design of the 106 pas pump bracket. I gave a quick lick of paint too. and danny90's feet.








And pics of where it will live in the bay with the coolant bottle in there too. All original corsa pipes are used and they are under no stress or tight or rubbing against anything, fits perfect and still on rubber mounts as from factory. I'm well happy with how it fits just got to wire it up now as I plan to have it switchable.
danny90
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Registered: 13th Sep 10
Location: tipton west mids drives: corsa 1.6
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20th Apr 11 at 22:20   View User's Profile U2U Member Reply With Quote
nice its coming along now n yh my feet ha
dale87
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Registered: 19th Feb 06
Location: West Mids :)
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20th Apr 11 at 22:21   View User's Profile U2U Member Reply With Quote
Double update action. Almost forgot to mention I bought some equal length shafts and some brand new gm wind deflector for £60 bargain! No pics of driveshafts yet but got a few of the wind deflectors. And my feet this time












dale87
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Registered: 19th Feb 06
Location: West Mids :)
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20th Apr 11 at 23:10   View User's Profile U2U Member Reply With Quote
pagey - lol at the intercooler belonging to you , was it you who i bought it off on ebay in oct/nov ish? payed £70 for it iirc?
pagey
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Registered: 30th Nov 04
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21st Apr 11 at 18:00   View User's Profile U2U Member Reply With Quote
Nah mate, I sold it for about £300 quid a couple of years ago, good buy £70! Good progress, I'm thinkin of the eps 196/Saxo setup for mine
Mark.W
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Registered: 3rd Jan 07
Location: County Durham
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21st Apr 11 at 20:25   View User's Profile U2U Member Reply With Quote
Great work bud keep it up :thumbs`:
Kieran
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Registered: 12th Sep 08
Location: Kent
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21st Apr 11 at 20:46   View Garage View User's Profile U2U Member Reply With Quote
Looking good lad!!
AlexW
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Registered: 25th Oct 08
Location: Essex
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23rd Apr 11 at 22:45   View User's Profile U2U Member Reply With Quote
Just came looking for something and noticed the latest updates.

Have the 106/saxo setup on my car, Really good having it switchable, Its nice to switch it off on nice long roads or when wanting a bit more feel.

Just make sure the wiring you use is thick enough, and don't let air get into the pump, It hates it lol

Coming on well
dale87
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Registered: 19th Feb 06
Location: West Mids :)
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24th Apr 11 at 08:37   View User's Profile U2U Member Reply With Quote
I plan to use to loom and relay off the 106 and run the relay trigger wire to an ignition live via a switch so all the really thick wiring stays in the bay and ill only need 1 small wire to the cabin. well thats my plan.

on another note, cam across a bit of a problem yesterday. when removing the actuator i heard the wastegate 'penny' valve fall off , does this mean i need a new turbo? or can i get a repair kit for the wastegate? or maybe drill the standard penny valve and nut and bolt it back in position? any help much appreciated.
dale87
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Registered: 19th Feb 06
Location: West Mids :)
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24th Apr 11 at 21:38   View User's Profile U2U Member Reply With Quote
Today I had a go at sorting the 'penny valve' on the k16. First I ground it flat and centre punched it then I drilled a hole smack bang in the centre at 5.5mm (penny valve 6mm where it attaches to actuator arm) which gave me a .25mm 'sleeve' left which I put a bolt through and then a nut exhaust side.


Pics














Do you think this will be ok?
I'd rather try and rescue this turbo as it still spins freely and has no cracks around the wastegate so I'd like to get a little use out of it and get the engine settled into the corsa. Obviously with nothing blocking the wastegate it would make no boost at all so you think this will last at least a few 1000 miles?
wwwNOOBcom
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Registered: 28th Oct 09
Location: Shettleston, Glasgow City
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25th Apr 11 at 00:33   View User's Profile U2U Member Reply With Quote
I just put mine flat agesnt the hole, put the arm over it and welded the shite out of mine and it holds boost like a bitch
pagey
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Registered: 30th Nov 04
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25th Apr 11 at 12:58   View User's Profile U2U Member Reply With Quote
What are the future plans dale... Wheels, interior etc...?

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