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ok thought i would get some questions so will copy bits from my mk3oc diary
the engine bolts in on the saab mounts using the standard vaux subframe so no modifications needed in the slightest here, mechanically its a very similar engine its the electronics that are different i have used the standard inlet manifold and just slighty rebent one of the brake pipes and also used the saab radiator as this will fit in the front of the astra as long as you remove the front slam panel to get it in and out, the engine is a very similar outer casting to a vauxhall engine so i would think that it would be to hard to get it into other vauxhall cars i think one in a corsa would be interesting
The other major problem i have is that the astra has a mechanical speedo from the gearbox where as the saab trionic(engine management) needs a speed signal so to run the engine this is taken from the ABS system and this is where the speedo gets its signal from, to combat this im going to fit the nearside abs sensor and the rings are allready on the driveshafts and the ABS ECU will be fitted and feed the signal back to the trionic ECU the car will not run correctly if it does not recieve a electronic speed signal
Auxilary belt = the car had all the mod cons so air con and power steering where as the astra doesnt nor do i want them, removing the air con pump and rerouting the belt for that i can order from saab but i dont need the power steering pump this i solved by dismantaling the power steering pump and removing the blades from the pump it was then moun ted on the car filled with oil and then sealed at both ends and its been like this for 1000 miles at least and have checked inside and its running fine with no major noise it getting to hot
im going to be mapping the car myself with the help of a program called T5 suite i have shown kev G how easy this is and it makes other cars look rubbish and the fact im going to be able to live map the car will be great, ive nearly finished my car pc which will run the mapping while im driving and also monitor all the engine sensors without having to have 20 dials on my dash
the hardest part of this conversion is the electrics but if you have a donor veichle and some good wiring diagrams for the car its not to bad only took me about 8 hours to probably do the wiring but about 3 weeks of checking and writing bits down i will go over a few bits so to help people
starting with dash wiring for your RPM that just comes from the ecu speedo is a electrical signal from the ecu so im guessing if you have electrical clocks shouldnt be a problem if you have mechanical like is still have im not sure. engine temp is the next one as the saab has a 2 wire sensor where as my astra was a single connection and earthed through the engine to solve this i kept the saab one in the manifold and then fitted the vaux one as well into the thermostat housing by drilling and taping a hole its technically on the wrong side of the the thermsotat but only slighlty under reads,
the electrics for the engine running you need to make up a wiring loom with 2 relays one to run the fuel pump and another is the main relay these pretty much control most of the engines controls and are the main voltage inputs for the engine, i used the standard astra circualr plug for the starter and alternator and then replaced the oil pressure switch with an aftermarket one
hope some of this helps the people who are looking to do the conversion and good luck
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