A Little Astra G v6 Conversion Info I Wrote

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Updated22/10/2009(my2ndv6conversiontooksomepicutesthistime)loadedthemup.
Heresalittlev6info,Atfirstiwroteitformyselfsoeverythingiknewwasinoneplaceandididnt
forgetanythingatthetimeoftheconversion,Thiswirteupisaworkinprogressandichangequite
regular,Imsorryforanygrammerandspellingmisstakes,Imnotthegreatestbutitryedmybest
lol
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Inmyeyesyourbetterofusingthex25xev6outofthevectrabifyourwantingtov6aastragfor
anumberofreasons
*Thecavinlet(c25xe)cansometimeshitthebrakeservo.
*ThevectraC(z32se)willtakeabitofwiringin.
*Thex26xeisflybywire,Plusyoucantdecatasitwontrunrightandemlcomingup,Duetoall
thelamdasensorsbeforeandafterthecats
(remembertogetthetheecu,transponderfromaroundtheignitionbarrelandthechipfromthe
key)
Ilikesaidusethex25xestuffbutwhywasteyourtimewitha2.5L,Whenyoucanfitthe3.0Lor3.2
fromaomega(Likeidid ).Whenusingtheaboveengineitswireforwireapartfromthetemp
guagewhichworksoffmilliamps,TogetpastthiskeeptheoriginalastraECUpluggedintorunthe
tempgaugeandCTSbuttherestofthewiringcanbechopped,ItwillhaveloadsofFaultcodesbut
itwillstilldrivetheclocks.
luckleyineverhadtotapthesensorinijustreplacedthevectradashtempsensoronthewater
coolentbrige
KWWSZZZDVWUDRZQHUVFOXEFRPYEVKRZWKUHDGSKS$OLWWOHDVWUDJYFRQYHUVLRQLQIRLZURWH

Plustherevgaugewillreadwrongasyourclockswillreadasignalfroma4potengineandthev6
is6potsoitisgetting2morepulseseverycycle/revyoucangetpastthisbyusingapulse
convertoroffdomonhttp://www.migweb.co.uk/forums/items...adjusters.htmlorgotohiswebsite
http://www.picbits.co.uk/andlookundergadgets,Thenyouhavetochangetheflybywirepedal
forthecabletypesomecarscomewithitalready(mostlyearly1.6petrols)andthepartnumberis
90530835(around25),ThereIsalreadyaholeforthecableinthebulkheadbehidethedriverside
strutyou'llhavetogettherubbergrommetofthecableinsteadoftheblankingone.
Asyoucanseetheholecomingintothefootwell(CanalsobeusedforcablestopowerICE)

NOTE:(Ivepostedallyouneedtoknowaboutthewiringtotheengineintothecar,atthebottomof
thepage)
Justusethef23gearboxthatmostmk4comewithi.eGSI'sandsomediesels(Butnotthe2.2as
thestartermotorisinthewrongplace),Youcanusethe(Early)flattypeflywheelfromaredtop
(C20XE)as
thenewershape(Z20LET)flywheelsareonlya6boltpatternandthev6isan8boltpattern.
Youwillalsoneedthec20xepressureplatetomatchtheflattypeflywheel,Butyouhavetousethe
Calibraturbo(c20let/f28box)frictiondisctomatchtheinputshaftfromthef23gearbox(Thef23
andf28haveadifferentnumberofsplinestothef20/f18/f25),Orjustusethewhole(C20LET)
flywheelandclutchsetup,Buttheyusethepottypeflyandisheavyerthantheflattype(pot
9.6kgs,flat6.5kgscomparedtothev6fly15.6kgs)
Thedifferencesbetweentheflatandpottypes(Cantfind1ofthev6item)thev6isalmostthetwo
combined
Theclutchsetupsthatihavementionedcanalsobeusedwithotherengineconversionwherethe
f23isused(ieC20LET/C20XEinaastramk4,Eventhezafira,)

NOTE:Dontusethev6flywheelboltstheyhaveabigheadandtheypretrudetoofarandcanhitthe
clutch,usetheC20LETboltsinsteadasthereflat(Partnumber90511423)
Sostraightawayyouhavealightend/lighterflywheelasthev6oneweighsatonne.Thislinkisto
onetheofpagesonMARKT'sWebsite,itwillhelpalot
http://77.96.230.10/sytemsandsoftwar...F25WithF20.htm
Heisaveryknowledgeablepersonandhissitehasgotmeoutofsomestickysituations.
Ifyourcarusesthef23gearboxalreadyyouwontneedtochangethedriveshafts,Butifnotyou
canusethevectrabv6shafts(likeidid)astherethesamesizeastheastrag,Plusyouhavethe
addedbenefitofequallenghtdriveshafts(lesswheelspinandselltorquesteer).Thebellhousing
onthef23gearboxis23mmshorterthanthef25soyouwillhavetospacetheshaftmountover
23mm(youcangetthemoffebay)soitmeetsupwiththemountholesonthebackoftheengine.
Thewayimountedtheenginewasbymakingamountthatboltsoriginalastradriverssiderubber
mountusingtheholesontheenginewherethevectratorquemountgoesandoneofthemount
holesinthepowersteeringdeletionbracket(moreaboutthedeletionbracketlater)andtherestis
justheldinbytheother3mountsonthegearbox,
Here'smyenginemount(note:ThefarrightboltofthePSDbracketisntinasihadtocutitdown)

Youhavetospacethemountawayfromtheengineasabeltgoesthroughthemiddleofitlikeso.
Herealiketosomeotherastramountshttp://www.astraownersclub.com/vb/sh...d.php?t=191587
Droppingtheengineinwaseasytheonlythingyouhavetotakeoffisthetophalfoftheinlet
(unlikethecorsawhereyouhvaetofitthebearblockandbuildituponceitsin)
Thenputtheinletbackon

Theastraguseselectricsteeringsothereisnoneedforthepowersteeringpumpontheengine
therearetwowaystodothis:
1.Thepowersteeringdeletionbracket(I'llhavetogetthepartnumberforthis).
2.Justloopthepipesonthepumpwithasmallreservoirforoiltokeepitlubricated.
(note:thatyouwillhavetomakeaslightlydifferentenginemountifyoudontusethedeletion
bracket)
HeresthePSDbracket,Themountinthepicasfromthevectracgsi,Mymountboltsinthesame
places(redarrows)andthebracketinyellow
Forthebrakesyourbetteroffgoingforthe5studsetupifyoudonthavethemalready,youwill
alsogetreardiscsifyoudonothavethemalreadyandyoucanrunbigger308mmdiscs

Plusyouhaveabetterchoiceofwheelstochosefrom,Someastra'sdonthaveabsandyoucan't
getaspeedsignalfromthef23soyouhavetofitaabshub(ifyougo5studyouwillalreadyhavea
absringon)togetasignalfromandrunittotheclocksbutthesignalisveryweakwithouttheabs
ecusoyouhavetorunaamp,ThediagramtomakeyourownisavalablefromMarkTonAOCor
askhimtomakeyouone(i'mgoingtoaskhimforpermissionificanpostalinktothediagram)
AndDomthatimentionedbeforeiscurrentlymakingaprototype
http://www.migweb.co.uk/forums/other...mselling.html
Wiringtheengineintothecariseasyitswireforwire.
Theecuonmostastraisinthepassengersidewing,ipulledallthewiresintotheenginebayfrom
whenichoppedthewiringforthetempgauge,IwiredtheV6infromthere.
Pictureofthewiresbeforepullingthemthrough
VectraBEngineLoomConnectors
X7InstrumentsandDiagnosticsConnector
1.Red/BlueFuelpump.
Wiredtofuelpump.
2.BlackIgnitionsupplytoDISpack
ignitionlive.
3.Brown/WhiteDiagnosticsData.
ConnetedtoBrown/White.
4.Brown/YellowDiagnosticsBlink.
ConnetedtoBrown/Yellow.
5.Brown/BlueEngineManagementLight.
Wiredtoenginemanagementlight
6.GrayTractioncontrol.
Leftdisconneted.

7.NotUsed.
Leftdisconneted.
8.Red/BlackSAIValvesolenoidNotUsed.
Leftdisconneted.
9.NotUsed.
Leftdisconneted.
10.Blue/RedImmobiliser.
Wiredupto7onTransponderBlueconnector(SpeedsignaltoEngineECU(Transpondersignal).
11.BlueCoolanttemperaturesensor.
Leftdisconneted,Runningorignalastragecurunthis.
12.Black/BrownFuelsignal.
Leftdisconneted.
13.GreenRevCounter.
Connectedtogreenrevcounterwithinlinepulseconverter(offdomonmigweb).
14.NotUsed
Leftdisconneted.
15.black/blueACFanPressureSwitch.
Leftdisconneted.
16Brown/VioletCompressorClutch
leftdisconneted
17.%ODFNCoolantpump
Leftdisconneted.
18.Notused.
19.NotUsed.
20.BlackAutoBoxIgnitionLive.
Leftdisconneted.
21.Black/WhiteACHigh/LowPressureSwitches.
Leftdisconneted.
22.Brown/GreySAIPumprelayCoil.
SAIispartofthecarloom,Youhavetocutthebrownrelayplugoutofthevectrafuseboxonthe
NSstrutandconnecta12vandignitionliveconnectiononbrownrelay,thenjointhebrown/grey
fromtherelaytobrown/greyintheX7plug(Youdonthaveto,buttheenginewillstillrunbutwill
beleftwithECUlightonallthetime).
23.Red/BlackSAIPumprelayCoil.
Leftdisconnected.
24.Red/BlackTractionControl.
Leftdisconnected.
PictureoftheX7plug.
http://i22.photobucket.com/albums/b3...c/DSC00019.jpg
PictureoftheTransponderBlueconnector
http://i22.photobucket.com/albums/b3...c/DSC00018.jpg
X5startingandchargingloom.Justswapoverfromorignalastraengineontothev6,Butheresthe
connectorsanyway.
1.NotUsed.
2.Blue/WhiteAlternatorD+
3.Blue/GreenOilpressureswitch.
4.Black/YellowIgnitiontoReverseswitch.
5.White/YellowAutoGearSelector.
6.Black/WhiteReverseLights.
7.Notused.
8.Black/RedStartersolenoid.
9.Notused.

10.WhiteAutoGearSelector.
11.Brown/GreenOillevelSwitch.
12.GreenAutoGearSelector.
13.GreyAutoGearSelector.
14.BrownOillevelswitch.
15.Notused.
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Thefollowingmemberslikethispost:
bellastra

VWXDUWFXUUDQ
hitherem/port
whatclutchsetupdiduusetomatethef23tothev6asiamjustabouttochangemyv6froman
f18toanf23.
doestheredtopturbofrictionplateworkinac20xeflattypeclutchandpressureplate.
ineedtochangemyfrictionplateasthesplinesaredifferent
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Thenewershapeflywheelsareonlya6boltpatternandthev6isa8boltpattern,Iusedtheflat
typeflywheelandclutchfromaC20XE.
IthinkthislinktoonethepagesMARKT'sWebsitewillhelpalot
http://77.96.230.10/sytemsandsoftwar...F25WithF20.htm
Heisaveryknowledgeablepersonandhissitehasgotmeoutofsomestickysituations
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whatfrictionplatediduuseasiamusingthesameclutchsetupformyf18box
cheers

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Youwillneedtousethe(Earlypre93)flattypeflywheelfromaredtop(C20XE),Youalsoneedto
usethec20xepressureplatetomatchtheflattypeflywheel,ButyouhavetousetheCalibraturbo
(c20let/f28frictiondisctomatchtheinputshaftfromthef23gearbox(Thef23andf28havea
differentnumberofsplinestothef20/f18/f25)
Orjustusethewhole(C20LET)flywheelandclutchsetup,Buttheyusethepottypeflyandis
heavyerthantheflattype(pot9.5kgs,flat6.5kgs)
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Heresapicturetoshowthedifferencebetweenac20xe(Early)flattypeflywheelandtheV6
flywheel
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couldiaskacoupleofquestions?
Ihavea1999TAstraGVan2.0DI.
Asidefromthefueltankissues,doineedtochangemuchotherwiringonmyvanotherthenthe
connectionslistedabove?
Also,Iamassumingthatthe2.0DIusesanF23gearboxsomyoutlaycostsshouldbeminimal?
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Anyothersuggestions/adviceforperformingtheconversion?

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Cheers
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hiihaveaastracoupe2.2andamputinga2.6v6gsiengineinitbutcantsourtotthewiringcan
anybodeyhelpmeplease
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hiimnewtoaocandwouldlikesomehelpihaveputa2.6v6inmyastracoupe2.251platbut
cantworkoutthewiringonthecarcananyoneouttherehelpmepleaseplease canyouplease
helpme
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A Little Astra G v6 Conversion Info I Wrote

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