Vauxhall XE Engine Conversion

Message

SMIFTER · #1 Post by **SMIFTER** » Thu Nov 03, 2005 8:50 am

Its been a long time waiting, but I've taken 3 days off work to actually get my hands dirty. 
 
I thought I'd start a diary of how it goes, this is likely to go on for months (knowing me possibly years!). Hopefully it'll be useful to anyone else contemplating fitting an alternative engine. 
 
Firstly I've been collecting all the necessary parts for the last 6 months via ebay, relatives, friends, friends of friends and various motorsport suppliers. 
 
The end result will hopefully be a dolomite with bullet proof engine reliability which will be quicker and a lot lighter on its feet than it ever was on Triumph power. It should also be fairly economical to do as there are plenty of these engines available for peanuts. 
 
There are some challenges in getting it to all work but I'm sticking my neck out and going for it. 
 
Basically the car will be fitted with an early Vauxhall C20XE 2 litre twin cam engine as fitted to 16 valve astras, calibras and cavaliers. The fact that a vauxhall somewhere has died so I can uses its engine makes it all the more worthwhile. 
 
The easy option would be to fit a mechanical dizzy, some 45's and off you go. I've decided thats just too easy, and I'll be fitting a DIY engine management system using a Megasquirt'n'edis system controlling spark via a ford wasted spark ignition system and fuelling via a set of 42mm throttle bodies from a Yamaha R1 mounted on a specially fabricated manifold. For an extra bit of fun I've got a Nitrous Oxide injection system which will work via a fogger jet in the inlet plenum jetted to give about 30bhp boost. With the NOS and properly tuned up engine management the engine should be capable of producing something in the region of 210 - 230BHP. 
 
Why bike Throttle bodies? Firstly the aftermarket throttle bodies are stupid amounts of money for what they are. A throttle body is not much more than a cast tube with a butterfly in it, much more simple than a carb, yet the suppliers want to charge from 700 to 1500 quid for a set. The bike bodies cost me £30 on ebay. No contest there! 
 
However I'll get onto that in more detail some other time. This weeks aim is to get the engine ready for transplant and hopefully get the engine mounts sorted and welded to the chassis. 
 
Yesterday afternoon was spent sorting parts out and swapping sumps. The sump on a standard XE engine sits the wrong was round for a Dolly subframe, so I sourced a steel sump and oil pick up pipe which came from an XE powered Talbot Sunbeam rally car. This was a simple matter of unbolting the standard sump/pipe and fitting the new. Whilst the sump was off I also removed the windage tray to give access to the big ends for inspection and to replace the standard crappy GM con rod bolts with some nice ARP bolts. £60 is a lot of cash for 8 bolts but they do mean the engine should stay together at 8000 rpm plus if I want it too. They are a doddle to fit - the instructions say it may be necessary to chamber the conrod cap holes to enable the bolts to fit properly but mine fitted without any need for modification. They have to be torqued up to 32lbft, loosened and retorqued 3 times to allow for bolt stretch. The bearings are all in good condition so no need to replace anything else. Thats the only mechanical mods I'm making to the engine - these engines were in a state of detune when fitted to road cars so there shouldnt be any need to change cams or anything else to get what I want out of it. 
 
The early engines like mine also have nice light flywheels and forged Mahle pistons as standard. The later engines use cheaper GM components designed to reduce noise and emissions rather than optimise power. 
 
I'll post an update on the weekend with some photos provided i dont drop the engine on my foot or something else typically me. 
 
Please no 'why didnt you use a Dodge Viper V10 instead' posts. 
 
Graeme

<a href="http://www.smifter1971.pwp.blueyonder.c ... >Smifter's Dolomite Sprint Website</a> 
 
Featherweight 1974 Dolomite Sprint - Soon to be XE'd, NOS'd, Megasquirted and 5 linked Lash up to scare myself (and my wallet) senseless 
 
2004 Smart Roadster (company car!!) - 698cc of turbo'd adrenaline fuelled rollerskate - destined to classic status thanks to Daimler Chrysler bean counters. 
 
1997 Audi A4 2.6 to chill out after the above and fill with baby products..... 
 
2005 Trek 1400 (ok its not a car but still fast) - 
a bit like Lance Armstrong but slower and fatter

tinweevil · #2 Post by **tinweevil** » Thu Nov 03, 2005 1:59 pm

I can understand why not the yank V10 but why on earth not the tasty lump out of <a href="http://en.wikipedia.org/wiki/Rolls-Royc ...  Phil could advise on the nose extension I'm sure. 
 
Seriously tho, good luck, watch your toes and any chance of some pictures? I'm sure you must have see it but <a href="http://www.club.triumph.org.uk/cgi-bin/ ... ll">here's a log</a> of a similar job on a Spitfire. 
 
Tinweevil

1978 <a href="http://www.triumphowners.com/704">Dolomite Sprint</a> 
1972 <a href="http://www.triumphowners.com/754">Spitfire IV</a> 
1968 <a href="http://www.triumphowners.com/705">GT6 II</a> 
1973 <a href="http://www.triumphowners.com/755">Dolomite Sprint</a> 
39 anorak points on the Nicholas scale

davepoth · #3 Post by **davepoth** » Thu Nov 03, 2005 2:20 pm

I think it's a pair of Audi V8s bolted together. Which was probably 2 skoda engines bolted together originally. 
Have VAG stolen BL's mantle for parts bin raiding?

Paul · #4 Post by **Paul** » Thu Nov 03, 2005 2:30 pm

good luck, i will be interested in this as i will be fitting an ecotec with arp conrod bolts, megasquirt n edis and homemade throttle bodies using either 1.5 or 1.75 inch Su spindles and throttle plates. 
 
Paul

Carsreunited · #5 Post by **Carsreunited** » Thu Nov 03, 2005 5:43 pm

Good to see you are on the road to madness again. Best of luck. Looks like I'll be getting blown away by you, Phil and Martin on trackdays!

SMIFTER · #6 Post by **SMIFTER** » Thu Nov 03, 2005 7:49 pm

I havent smashed my feet in yet but i did manage to set fire to my overalls when fabricating the engine mounts! All good fun. 
 
And I nearly rolled the Sprint into the audi - forgot to put chocks under the wheels (the handbrake isnt connected)! Whoops - that would have been messy. 
 
Spent most of the day today drilling out sheared off pulley bolts and cutting the n/s engine mount to fit - got it just right and tacked in now although my welder has decided not to cooperate and keeps jamming - bloody cheap crap! 
 
I've found a problem - the XE crank pulley and front of the sump clashes with the sprint subframe front crossmember - i've resorted to chopping out a section of the crossmember - I'll have to reinforce the subframe with an additional cross member beneath it so its not weakened. Also the standard XE oil filter doesnt fit - it clashes with the anti roll bar so I'll have to change to a remote oil filter. 
 
I've really enjoyed getting stuck in again - its been far too long! I just need to persuade Mrs S that Sunday afternoons are best spent getting oily now! I'll take some pics tomorrow to show how its going. 
 
Don't speak to soon Scott - looks like this might be a long job ahead of me! 
 
Paul - I suppose the ecotec is a development of the XE so you'll have the same issues. I still think the XE is a better engine but they are getting old - I'm fortunate to have sourced a good engine from a contact who has collected a few as spares. 
 
Graeme

<a href="http://www.smifter1971.pwp.blueyonder.c ... >Smifter's Dolomite Sprint Website</a> 
 
Featherweight 1974 Dolomite Sprint - Soon to be XE'd, NOS'd, Megasquirted and 5 linked Lash up to scare myself (and my wallet) senseless 
 
2004 Smart Roadster (company car!!) - 698cc of turbo'd adrenaline fuelled rollerskate - destined to classic status thanks to Daimler Chrysler bean counters. 
 
1997 Audi A4 2.6 to chill out after the above and fill with baby products..... 
 
2005 Trek 1400 (ok its not a car but still fast) - 
a bit like Lance Armstrong but slower and fatter

algtj · #7 Post by **algtj** » Fri Nov 04, 2005 10:03 am

Good luck. Ill be interested to see how you get on. I got a spare 2.0 GTE gearbox when you need the internals! 
Will the Sprint axle be up to the extra poke? 
All the best Al W

Carsreunited · #8 Post by **Carsreunited** » Fri Nov 04, 2005 1:38 pm

Darren. They are good for 400bhp and double the standard torque of a sprint although I think the half shafts may let go first. 
 
I'd definitely get an uprated custom prop though Graeme if you aren't already.. 
 
Scott

SMIFTER · #9 Post by **SMIFTER** » Fri Nov 04, 2005 2:41 pm

I have to get a custom prop - the manta box has a splined connection rather than a flange - I might go for a one piece prop to keep it simple and minimise power losses. 
 
Progress has been good today - managed to get the welder wire feed working to a degree. 
 
I'll have some pics for you later. 
 
G

<a href="http://www.smifter1971.pwp.blueyonder.c ... >Smifter's Dolomite Sprint Website</a> 
 
Featherweight 1974 Dolomite Sprint - Soon to be XE'd, NOS'd, Megasquirted and 5 linked Lash up to scare myself (and my wallet) senseless 
 
2004 Smart Roadster (company car!!) - 698cc of turbo'd adrenaline fuelled rollerskate - destined to classic status thanks to Daimler Chrysler bean counters. 
 
1997 Audi A4 2.6 to chill out after the above and fill with baby products..... 
 
2005 Trek 1400 (ok its not a car but still fast) - 
a bit like Lance Armstrong but slower and fatter

SMIFTER · #10 Post by **SMIFTER** » Fri Nov 04, 2005 5:24 pm

Here's some progress photo's 
 
ARP conrod bolt (right) vs Standard crappy GM bolt 
 
<img src="http://www.smifter1971.pwp.blueyonder.c ... pbolts.jpg" style="border:0;"/> 
 
Original ally sump with bowl at the rear - no good for a Dolly. 
 
<img src="http://www.smifter1971.pwp.blueyonder.c ... tdsump.JPG" style="border:0;"/> 
 
XE engine on crane with sunbeam sump with bowl at the front fitted 
 
<img src="http://www.smifter1971.pwp.blueyonder.c ... engine.JPG" style="border:0;"/> 
 
Engine mounts fabricated and welded in and subframe cut for clearance (more reinforcement will be needed before I'm done) 
 
<img src="http://www.smifter1971.pwp.blueyonder.c ... ineout.JPG" style="border:0;"/> 
 
Drum Roll...............................................TADA!!! 
 
<img src="http://www.smifter1971.pwp.blueyonder.c ... ginein.JPG" style="border:0;"/> 
 
It all fits quite nicely - next job will be getting the gearbox in with mods to the bulkhead to suit because the engine sits so far back in the engine bay - and then taking it all out again to paint the engine bay. I wont get the chance except saturday mornings from now on so progress is likely to be a lot slower. 
 
I've also learnt screwdrivers are for turning screws and not stabbing yourself in the finger with. Don't click the link if you dont like the sight of blood!! <a href="http://www.smifter1971.pwp.blueyonder.c ... E/gore.JPG" target="top">Bloody Mess</a> 
 
Graeme 
 
 
 
 

<a href="http://www.smifter1971.pwp.blueyonder.c ... >Smifter's Dolomite Sprint Website</a> 
 
Featherweight 1974 Dolomite Sprint - Soon to be XE'd, NOS'd, Megasquirted and 5 linked Lash up to scare myself (and my wallet) senseless 
 
2004 Smart Roadster (company car!!) - 698cc of turbo'd adrenaline fuelled rollerskate - destined to classic status thanks to Daimler Chrysler bean counters. 
 
1997 Audi A4 2.6 to chill out after the above and fill with baby products..... 
 
2005 Trek 1400 (ok its not a car but still fast) - 
a bit like Lance Armstrong but slower and fatterEdited by: <A HREF=http://p206.ezboard.com/bthetriumphdolo ... SMIFTER</A> at: 4/11/05 5:34 pm

MaddMart · #11 Post by **MaddMart** » Fri Nov 04, 2005 6:34 pm

Well done Graeme, it's looking good. Keep plugging away. If you need a hand any time give us a shout.

Martin 
 
<a href="http://www.dolomitesprint.com/" target="top">www.dolomitesprint.com</a>

davepoth · #12 Post by **davepoth** » Fri Nov 04, 2005 8:18 pm

Looks like Smifter will need a hand, judging by the link above...<img src=http://www.ezboard.com/intl/aenglish/im ... s/roll.gif ALT=":rollin">

algtj · #13 Post by **algtj** » Fri Nov 04, 2005 9:30 pm

Looks good, was that v shape cut all you needed to do to the subframe? 
Oh and OUCH!!! <img src=http://www.ezboard.com/intl/aenglish/im ... /happy.gif ALT=":D">

SMIFTER · #14 Post by **SMIFTER** » Fri Nov 04, 2005 9:45 pm

I had to completely cut out about 18 inches of the front crossmember to clear the front pulley and sump and cut off the offside engine mount bracket from the subframe to allow clearance for the XE's oil pump. 
 
After I'd done that and chopped and modified the escort engine mounts to fit it all seems to go in nicely. 
 
I wish I could spend 3 days every week on it now! The list of jobs to do on it gets longer the more I think about it!

<a href="http://www.smifter1971.pwp.blueyonder.c ... >Smifter's Dolomite Sprint Website</a> 
 
Featherweight 1974 Dolomite Sprint - Soon to be XE'd, NOS'd, Megasquirted and 5 linked Lash up to scare myself (and my wallet) senseless 
 
2004 Smart Roadster (company car!!) - 698cc of turbo'd adrenaline fuelled rollerskate - destined to classic status thanks to Daimler Chrysler bean counters. 
 
1997 Audi A4 2.6 to chill out after the above and fill with baby products..... 
 
2005 Trek 1400 (ok its not a car but still fast) - 
a bit like Lance Armstrong but slower and fatter

algtj · #15 Post by **algtj** » Sat Nov 05, 2005 7:30 am

Keep plugging away, but not at your hand!!! 
Wish I lived closer I would be around at weekends to give you a hand. 
Do keep this post updated its inspiring me to bigger and better things for my 1500. <img src=http://www.ezboard.com/intl/aenglish/im ... /happy.gif ALT=":D">

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