Still battering away at sons AstraDisaster. The replacement engine we got for it was from a 2005, and its a 2004.
At first I noticed the dipstick was on the wrong side of the front of the engine, but figured it would become clear when I got it in what was needed. Then a small tweak resolved that, and made up a different catalyst bracket as its part of the header and didnt line up to the new bracket and the old bracket hit the new dipstick, then finally pleased with myself, went to screw the exhaust on and this happened.
Spot the obvious difference I had missed. The side of the sump cutaway to miss the exhaust downpipe had changed along with the dipstick. Old engine was really oily but put it on a engine stand and cleaned the bottom off to take the sump off, and it was cracked almost the full width of the pan, oh naughty words. Apparently quite common for this era 1.6 ecotec's. Quickly pulled the motor out of his old Astra G 1.6 ecotec, and its different of course. The G having a flys head oil pickup hanging off the pump, and the H its integrated into the pan itself.
Cheapest secondhand sump of correct shape (had to be a 2004) I could find was 200 quid and a weeks delivery. Veeing out and welding alloy that long probably would result in it going spang and distorting badly and need machining flat, so a bit of a last resort.
Post 2005 the car came with a different exhaust, but as I'd also altered the catalyst bracket to suit the original cat prior to noticing the downpipe, and the new engine didnt come with a cat, no great confidence the mounting angles were same to just buy one.
Best course of action, chop pipe up for flexy and bends and make one, tacking it on the car and finishing off on the bench and make a reasonable job of it as its going for mot as soon as its done. The straight length is a piece of range rover 4-2-1 mid pipe which has been stopping a shelf in the storage from floating away for 20 years. Bodged but acceptable.
At first I noticed the dipstick was on the wrong side of the front of the engine, but figured it would become clear when I got it in what was needed. Then a small tweak resolved that, and made up a different catalyst bracket as its part of the header and didnt line up to the new bracket and the old bracket hit the new dipstick, then finally pleased with myself, went to screw the exhaust on and this happened.
Spot the obvious difference I had missed. The side of the sump cutaway to miss the exhaust downpipe had changed along with the dipstick. Old engine was really oily but put it on a engine stand and cleaned the bottom off to take the sump off, and it was cracked almost the full width of the pan, oh naughty words. Apparently quite common for this era 1.6 ecotec's. Quickly pulled the motor out of his old Astra G 1.6 ecotec, and its different of course. The G having a flys head oil pickup hanging off the pump, and the H its integrated into the pan itself.
Cheapest secondhand sump of correct shape (had to be a 2004) I could find was 200 quid and a weeks delivery. Veeing out and welding alloy that long probably would result in it going spang and distorting badly and need machining flat, so a bit of a last resort.
Post 2005 the car came with a different exhaust, but as I'd also altered the catalyst bracket to suit the original cat prior to noticing the downpipe, and the new engine didnt come with a cat, no great confidence the mounting angles were same to just buy one.
Best course of action, chop pipe up for flexy and bends and make one, tacking it on the car and finishing off on the bench and make a reasonable job of it as its going for mot as soon as its done. The straight length is a piece of range rover 4-2-1 mid pipe which has been stopping a shelf in the storage from floating away for 20 years. Bodged but acceptable.
the trick was (on a four cylinder) getting them all to weigh the same.
