corsaproject2010
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Registered: 21st Oct 09
Location: bristol
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right then, my 1.6 engine was f***'d..
so im in the middle of replacing it now, with another 1.6
(x16xe) corsa sport 98
ive got my old engine out, and in the garage, along with my new engine.
ive got a few parts to go on..
4-2-1
power box (one from flame)
ive also got to swap a few bits over,
gearbox
alternator
right hand side engine mount
(i think thats it off the top of my head)
problem 1
right so anyway first problem
the old manifold is bolted on to the block, and then when it goes into two pipes. its then not connected anywhere untill after the cat between the middle silencer..
so, if i stick the 4-2-1 on its not going to connect to anywhere enless i cut the old exhaust (around the flexi pipe) judging from eye.
what can i do there? would it be ok to drive to exhaust garage to get them to weld it together then, or should i just leave the 4-2-1 off? i dont really want to then have to pay someone extra to fit it seeing as its already on the car atm
problem 2
with the power box, ive got the upper inlet off.
im now left with these three bolts sticking up
(i want to stick bolts down through the power box into the holes where these are coming from)
i have no idea how to get these little buggers out?
problem 3
general oil spills etc..
the floor is getting slippy in places now where oil coolant etc has split onto it. ive tried to mop it up, but not having much luck, any suggestions on what i can use to soak it up and make it a bit safer?
thanks in advance 
[Edited on 30-10-2009 by corsaproject2010]
[Edited on 30-10-2009 by corsaproject2010]
[Edited on 04-11-2009 by corsaproject2010]
[Edited on 05-11-2009 by corsaproject2010]
[Edited on 15-11-2009 by corsaproject2010]
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smcGSI16V
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Registered: 26th May 03
Location: Farnborough Drives: Thurlby 888 CDTi No.98
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Problem 2
you need to put 2 nuts onto the thread, tighten the 2 nuts together then put a spanner on the bottom nut and it should undo the threaded rod.
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smcGSI16V
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Registered: 26th May 03
Location: Farnborough Drives: Thurlby 888 CDTi No.98
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Problem 3
cat litter.
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corsaproject2010
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Registered: 21st Oct 09
Location: bristol
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awesome, you can see i tried one nut on the middle thread..
it started to round off though so thought i better leave that,
i will give the double nut a go 2moro, thanks.
cat litter - awesome, got plenty of that. thanks.
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Richardhhha
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Registered: 29th Sep 07
Location: Croydon, Greater London
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problem 1
just bolt the new exhaust into place as they are direct fit exhausts unless you have a mega expensive custom one
problem 2
you can use the 2 nut method or just wang a set of mole grips on the fuckers
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corsaproject2010
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Registered: 21st Oct 09
Location: bristol
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right so here is the current exhaust
and here is the end of the new one
it finishes pretty much right next to flexi pipe (looking at it)
however the flexi is welded in..
so thats my problem, i cant just bolt it straight on, it needs to be welded, would it be ok to drive to garage to get it welded or should i stick standard manifold on?
cheers
[Edited on 27-10-2009 by corsaproject2010]
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corsaproject2010
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Registered: 21st Oct 09
Location: bristol
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right so i tried to nuts..
that just snapped the thread 
i used mole grips on the other two threads no problem
however with the snapped one, there insnt enough thread for it to grab on it,
thats what ive got to play with...
the mole grips are just butchering it really.. not getting any where with those
any ideaS?
cheers
sorry about poor pics, camera phone couldnt focus on it..
[Edited on 27-10-2009 by corsaproject2010]
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Richardhhha
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Registered: 29th Sep 07
Location: Croydon, Greater London
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Thats one butchered exhaust.. The 4-2-1 is as the car was standard, but ether you or the person you bought the car off has had that exhaust butchered into place, i take it the exhaust system has no cat so is illegal and does it have a center box or is it just a scafolding tube for a center exhaust?
A proper exhaust should be sleeved after the cat and then on one of the bends near the back box.. Unless its custom made from stainless steal then there isn't any point to welding the whole exhaust in..
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alan-g-w
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Registered: 9th Nov 07
Location: Glasgow
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Easi-outs for the fucked stud mate. Either that or find the exact centre of it, centre dab it then very carefully drill it out.
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corsaproject2010
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Registered: 21st Oct 09
Location: bristol
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right...
its got the cat just after the flexi there before the center box, and a standard back box :/
(i will messege the guy i got the car from see what he says about the exhaust)
can i pick up the easi out kit from halfords? or wickes or somewhere like that?
ive only got the crane untill fri so need to crack on, dont really want to have to hire it out again.
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Richardhhha
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Registered: 29th Sep 07
Location: Croydon, Greater London
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plonk the engine in as it is because the inlet and the exhaust can be done after its in the car...
the cat is sposed to bolt onto the flange of the 4-2-1 fella so your going to need a new one of them too.. im curious to hear why the exhaust has been done like that as ive only hered of xe' and let's having this done due to there manifolds not lining up with the corsa's exhausts..
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corsaproject2010
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Registered: 21st Oct 09
Location: bristol
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right i got a stud extractor kit from screwfix which should do the job..
http://www.screwfix.com/prods/20084/Van-Car-Accessories/Mechanics-Tools/Stud-Extractor-Set-8-Pc?cm_re=SEARCHPROMO-_-STUD%20EXTRACTOR-_-20084
if it doesnt i can always take off the lower inlet from the old engine and stick it on the new.
before the new one goes in ive got to get a couple more hoses and wiring from the back of the old engine and stick it on the new one..
work 2moro.. so engine can go back in on thurs.
oh right ok, thats interesting, ive sent a messege to the fella i got the car from, just being curious not pointing a finger.. just interested, so hopefully he wont ignore me and will get back soon.
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corsaproject2010
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Registered: 21st Oct 09
Location: bristol
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with the power box ive got it came with throttle body..
do i need to take my old one off or can i leave it in place?
cheers
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corsaproject2010
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Registered: 21st Oct 09
Location: bristol
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richard i see you have one is there any chance of some up close pics so i can see where everything goes?
cheerrs
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Richardhhha
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Registered: 29th Sep 07
Location: Croydon, Greater London
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What do you need pic's of fella?
You will need to remove the original throttle body, take a look at warren g's tutorial and it explanes quite a lot body show's you what to do. But if you get stuck im sure i can help. Oh and if you need a new exhaust (which you will by the looks of use one that came off your car) i have one for sale
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corsaproject2010
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Registered: 21st Oct 09
Location: bristol
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just a pic of where all the hoses are going, im not to sure on those..
why does the throttle body need to be removed?
(hope that doesnt sound like a twat) i just dont currently have the right torx pieces, and there is one already bolted on the power box..
and regarding the exhaust is it a decat or normal one?
i ordered a decat which should be here 2moro just so i can get the thing going again.. .
cheers
[Edited on 29-10-2009 by corsaproject2010]
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Richardhhha
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Registered: 29th Sep 07
Location: Croydon, Greater London
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Its a cat back stainless system mate and its an ace bit of kit, umm let me get to a pc and i can post you the link to a video i made with all the hoses in the right places. And the reason that the throttle body is to be removed and blanked off is because there is a hole in the side of the head where the egr puts the gasses back into the induction system. Plus it means you can work on the car easyer.
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corsaproject2010
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Registered: 21st Oct 09
Location: bristol
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ah right ok fair enough will have to get some more torx bits tonight then.
engine is ready to be lifted back into the car and bolted in now
is the exhaust very loud? i want to try and keep it as quite as possible really..
the vid would be awesome!
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Richardhhha
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Registered: 29th Sep 07
Location: Croydon, Greater London
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The exhaust is nice and quiet im not one for having a exhaust that when you start it the police can hear you from another county, plus it makes a nice burble, will get the vid up for you when i can get my hands on the laptop, misses is playing with it atm..
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Richardhhha
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Registered: 29th Sep 07
Location: Croydon, Greater London
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here's the video mate,
hope it helps
http://www.youtube.com/watch?v=sujEtBzSUvY
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corsaproject2010
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Registered: 21st Oct 09
Location: bristol
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ha! i was watching that the other day when searching for power boxes, totally forgot about it, thanks!
engine is back in now..
the new one didnt have a mount on the right hand side
so had to swap those over from old engine to new and then it was ok.
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corsaproject2010
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Registered: 21st Oct 09
Location: bristol
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dam pics up side down, the one on the left is the one with the mount..
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corsaproject2010
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Registered: 21st Oct 09
Location: bristol
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right then a couple of new things.. a few plugs i cant seem to find a place for them to go :/
this one comes out around the left hand side suspension strut.
then there is this one on the other side of the engine
then there is this one again on the right hand side of the engine.
and then the wire going up here..
a close up of it, i dont remember snapping it :/
also this big bugger
and then with the power box should that hole be blanked, ive seen on some peoples they have tubes there???
and last but not least a pic from the haynes which might be helpfull trying to describe where stuff goes..
thining about it one of those plugs is for the fan.. but not sure on the others.
thanks :d
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Richardhhha
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Registered: 29th Sep 07
Location: Croydon, Greater London
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first pic is of the air temp sensor that goes in the ducting from the throttle body to the air filter housing..
second pic is of the fuel tank vent valve plug..
and the earth you have seen thats broken well that goes onto the side of the lower inlet (gearbox end)
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corsaproject2010
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Registered: 21st Oct 09
Location: bristol
User status: Offline
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''first pic is of the air temp sensor that goes in the ducting from the throttle body to the air filter housing..
second pic is of the fuel tank vent valve plug..
and the earth you have seen thats broken well that goes onto the side of the lower inlet (gearbox end)
''
awesome right thats those sorted
its just the big fat 6 pin one (square with green trim)
and the round one with the pin in the middle which is left, ive had a look on the old engine and cant seem to see where they go on there
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