Here we go... My ZS+ TD (2003) in Le Mans Green

[mattyprice4004]

Well, thought I better make a thread about my car, and it's pretty long journey to it's current state.

I bought the car in October 2009, and since then I've been working on it, trying to take off some of it's 113k, and doing little itty bitty jobs like cambelt changes etc.

The car is a 2003 reg'd ZS+ TD in Le Mans Green, it has 4 electric windows, air con but oddly enough... no foglights! No matter... :happy:

http://i282.photobucket.com/albums/kk245/mattyprice4004/IMG_0049-1.jpg

First job, get that cambelt changed. This is a simple afternoon job... if you don't go and order the wrong belt! I got 114 teeth, instead of the 112 teeth I should have ordered. The tensioners seemed OK, a little play, but 20k later, the idler has started whining. I'd therefore replace them whenever you do a belt change if in any doubt.

I also fitted a Powerflow exhaust, as the original had rusted through in several places at the mid and backbox.

The charge pipe was loaded with gunk...
http://i282.photobucket.com/albums/kk245/mattyprice4004/DSCN1143.jpg

So I burned it out. :strongbench:
http://i282.photobucket.com/albums/kk245/mattyprice4004/DSCN1146.jpg

Then, after a little debating, decided to buy these!
http://i282.photobucket.com/albums/kk245/mattyprice4004/BfsOrQBWkKGrHqUH-EUErgzZ7NkhBLCWwRb.jpg

A set of SDi injectors with just 60k on the clock. ?25 from eBay, scoooore.

About 8 weeks after getting the car, I lost all drive while out at 3am, and had to rely on my trusty breakdown service to get home. Clutch cylinders were fine, so it appears I've broken something pretty well...

http://i282.photobucket.com/albums/kk245/mattyprice4004/DSC00220.jpg

Anyway, I set about pulling the gearbox off, and found lots of metal dust, bits of black metal, and friction material. Oops! :whistle:

http://i282.photobucket.com/albums/kk245/mattyprice4004/DSC00231.jpg

This is what the clutch looked like when I got it off...

http://i282.photobucket.com/albums/kk245/mattyprice4004/DSC00241.jpg

That'll be the problem then! :smile2:
Nice new Valeo to replace it (people have used upto 300 lb/ft OK with OEM units)

http://i282.photobucket.com/albums/kk245/mattyprice4004/DSC00242.jpg

Everything nice and greased up.

http://i282.photobucket.com/albums/kk245/mattyprice4004/DSC00240.jpg

You can see the scoring on the bellhousing caused by the flying bits of metal!

http://i282.photobucket.com/albums/kk245/mattyprice4004/DSC00237.jpg

It's worth noting this clutch failure was caused by the release arm being seized, and thus overheating the clutch and causing catastrophic failure as seen.

After all this, time for a dyno run!

http://i282.photobucket.com/albums/kk245/mattyprice4004/DSC00313.jpg

Made 141.8bhp at the flywheel, that's just with SDi injectors.

Recently I sold my 620ti, which was my 2nd car, so I've been after more power from the ZS. The Zed had been sat in my garden for the last 3 months (if you've had a 620ti, you'll see why... so much fun!) so it needed a good clean up. The downpipe was also blowing a little... lmao!

http://i282.photobucket.com/albums/kk245/mattyprice4004/IMG_0714.jpg

I've also developed a clutch pedal bracket to lower the high clutch position that plagues the Rover 400/45/MG ZS, fitted this and it's a lot nicer to drive. You don't have to be double jointed to reach the clutch pedal now!

More info: http://forums.mg-rover.org/showthread.php?t=374061

Much more work coming soon, I'm going to be aiming for around 160bhp when I'm done, currently at about 150 estimated.

Hope you enjoyed reading!
Mat

[Andyf]

Nice little project, i'd be worried about this photo though

http://i282.photobucket.com/albums/kk245/mattyprice4004/DSC00313.jpg

It's like the ones from Final Destination where the faces of the survivors blur in pictures!

[Huffy]

Great stuff! i'll be interested to know what i'm pushing with my mods.... can only hope they're as god as yours!

[peterzs]

Hi Mat, interesting read, I've got a Mk2 derv, do go well.

My clutch always feels heavy, can you grease the release arm, or is it sealed???

http://i297.photobucket.com/albums/mm214/peterzs/1-1.jpg

http://i297.photobucket.com/albums/mm214/peterzs/Copyof2.jpg

Thought of getting some SDi's but I've got to go slower, rather than quicker for a bit. :mml::mml::mml::mml:

:yes::yes::yes:

[baz69]

Nice car. Good work

[p_b82]

if the pressure relief plan goes as expected you could get 160 on the stock turbo, as we expect that the EMP is actually really causing the engine a lot of extra work....

need to chase Matt to see if he has got anything more concrete yet, or whether he has been stuck at silverstone this week again....

I know that some-one has to push the boundaries with tuning, but there are many times i wish i had saved the cash and just done SDI's remap and left it there, and spent the money on summit else...

tho who am i kidding... i would have blown it on another car project i am sure :laugh:

[Boot Hill Bandit]

Nice!!!!!!!!!! Lovin that dude! good work on the car! wish my ZS180 had more torque and power!