Answer: Our suggestion would be to consider using the 1.6L 16V Corsa engine, rather than going for the 2.0L 16V. The 1600 engine drops straight into a Nova and the power to weight ratio is very good and it is an extremely tuneable engine. The 2.0L engine is large and heavy in comparison and often creates problems because the Nova becomes front end heavy. There is also a problem with being able to put the extra power down.

Answer: We would normally advise the use of a cosworth head casting. Simply because we know they don't have a problem with porosity. There are actually only a few cylinder head casting of the normal Carl Schmidt version that have become porous. The only problem is that many of these are dumped onto the second hand market and the same head castings get recirculated, so it looks like there are more than there actually are. Although you can have the cylinder head tubed and many companies are now claiming to be very successful, its the aggravation of getting it done and if it ever does become porous again, you have got to take the whole head apart again.

Links: Coscast head information

Answer: We have several people carry out a similar conversion of the type you are requesting. The components on our part of the conversion are fairly straightforward. We can supply an ECU, wiring harness, throttle bodies and a few other accessories required. But because your engine is quite old, at the time of its production the electronics used were fairly basic. What we suggest to most people carrying out this kind of conversion is to raid some of the components from the later 8V engines, fitted to either the Corsa or the Nova. This will help to keep your costs down.

The components I suggest you try and source are the distributorless coil pack and HT leads, as well as the mounting brackets. The front trigger wheel/bottom pulley and crank sensor. This will then make your engine ready for fitting the electronics. The only thing we haven't got access to is an inlet manifold to mount carburettor style throttle bodies. You will need to scour the second hand market for a manifold to suit your application.

The prices of the ECU, wiring harness, throttle bodies, throttle position sensor, fuel rails, fitting kit and a base programme to start the engine are available on a downloadable price list on our Web site. With the latest equipment we have, it will be possible to map your engine either on the road or rolling road, to make the engine drive smoothly and produce as much power as possible. All the cars we have programme so far, for the 8V 1600 engine, have usually had cam and head work as well, because of this in the programmes we supply for you to start your engine with, it would not be exact because of the variations in the engine specification we have already programmed.

Links: 1.6L Taper throttle body kits

Answer: Several of our customers have fitted the high spec manifold, which was produced for the Astra. It does hug the block and sump very closely and you may need to be careful to make sure you have sufficient clearance on your anti roll bar, but I haven't heard of anybody not being able to fit one. This is also the correct type of manifold, which will allow the TP208 kit to produce its full potential. Part number EX-M-AST3-S16V. This will be discounted if purchased at the same time as the 208 kit.

Links: 2.0L Taper throttle body kit | Exhaust manifolds

Answer: The 1.4L is becoming quite popular now, especially in Ireland and we are developing a new range of conrods and pistons. This is because the current rods are identical to the 1.6L and effectively are too short, which means the piston is far too heavy. In the tests we have carried out, we believe we are losing at least 10bhp. So the new rod we are producing is 5mm longer with a very short light piston. This will then allow you to reap the benefits of a strong engine with a good cylinder head. To give you an idea, our current 1.6L engine produces 256bhp. Now obviously I don't expect you to go for this kind of spec on a 1.4L since the cost is quite expensive at this level. But a standard engine with throttle bodies will produce about 130 - 135bhp. The second stage of tune, which is some mild cams and pocketed pistons, will produce about 150bhp. I would suggest you look at one of these two kits to begin with. After which each kit is upgradeable as your budget allows.
You would obviously need additional parts, such as up-rated exhaust manifold, air filter assembly and you would then need a free flow exhaust system, approx. 2.5" diameter.

Links: 1.4L Taper throttle body kits | Pistons | Conrods | Exhaust Manifolds | Air filters