My MG ZS repair diary

[dida4g]

http://www.themgzs.co.uk/vb/showthread.php?t=15276

Following on from this thread I had the car delivered on Friday, looks as good as the pics really.
Started 1st time...sweet, clutch feels good too.

Mk1 straights,:D
Full stainless steel exhaust,:D
Unknown cone filter,
Aftermarket short red aerial,
Kenwood Disc changer with disc holder missing.
Dog hairs on all the seats.

This is how it looked before I stripped the front end.

https://i.imgur.com/2FccmtI.jpg
After
https://i.imgur.com/M3qSqDr.jpg



This pic is the alternator belt cover so you get an idea of how fare the front panel went back.
https://i.imgur.com/SDDdwMM.jpg

Time to break out my 3 part jigging tool.
1 R400D,
1 tow rope,
1 wife to drive the R400D.....sorry no pics of the wife.
https://i.imgur.com/gzlXgPC.jpg



The front bumper will be repaired as the main curvature is still intact.
Things I need,
Bonnet,
O/S headlight,
front bumper bar,
Radiator with AC and twin fans,
OEM rear lights or swap for the Lexus style ones.

[ZS]

I used a very similar tool to "Jig" a Rover 25... although it was a Yellow rope, an MG ZS180 and a friend driving :D:D

[Maxfly]

Love the jig tool:D Look forward to seeing the end result of your labours with this:)

[peterzs]

Think if my wife was the jig, I'd end up with a foot longer ZS and no rear on the R400D. :D:D:D

Hope it all comes out OK, have a great car when its finished.

:thumbsup::thumbsup::thumbsup:

[stamford]

Hope it all goes well for you, will be a good one when finished.

[dida4g]

Thanks guys.
Are the bonnets the same on the MK1/2? just different grill.

[Maxfly]

Thanks guys.
Are the bonnets the same on the MK1/2? just different grill.

Yep mate, same bonnet:)

[daytona365]

looks good already, keep us all informed and look forward to seeing it when finished.

[Andyf]

think if my wife was the jig, i'd end up with a foot longer zs and no rear on the r400d. :d:d:d

hope it all comes out ok, have a great car when its finished.

:thumbsup::thumbsup::thumbsup:

lol!

[fastmike]

Nice one (Y)....... I,ve used that myself a few times .... And that looks like it,l be a nice car when its finished

[dida4g]

Things I need,

front bumper bar,
Radiator with AC and twin fans,


Bit of good luck yesterday,
Bumper bar £10.
Rad and A/C with twin fans, airbox and spare air flow sensor all for £60.

[peterzs]

Sounds a bargain, be up and running soon.

:yay::yay::wave::wave::wave:

[andys1981]

i used a ratchet strap,a tree,and one of my mates to pull the back end out on my old zs,worked a treat

[talkingcars]

I must admit I find the idea of car and rope a bit scary as a jig, so easy to over do it, I prefer the ratchet strap and tree or 4x4 with electric winch methods.

[ZS]

I've used the car method a couple of times when I have done bodywork for friends before :)

Its fine, you just get the owner of the car your fixing to drive the "jig" car... that way they pay extra special attention to what you say and if they pull too far you can blame them ;) lol

[dida4g]

Quick update.
Fitted the AC condenser and Rad, I now have heat....Woohoo, couldn't get the fan to came on even after half an hour, the temp stayed below half though.
I pressed the AC button and the fans spin, just needs a re-gas and it's good to go.

[peterzs]

My derv always runs about half way on the temp gauge, even in the hot weather last year.

Think the only time its come on was after a few laps at Brands, when they recommend just sitting with the engine running, after you finish.

Good to see one going back on the road, for a change.

:smile1::smile1::smile1:

[caled]

Thanks for keeping us updated, Ive been watching this with interest. All good work!
Looking forward to seeing how the bumper comes out.

[peterzs]

I got shot down on one of the forums (not this one) for suggesting the guy got his slightly damaged bumper, (just a crack), back from the repairers and fiberglassed it back up.

On the tv programme where they buy 2nd hand cars, do them up and flog them, the mechanic guy even showed you how to do it.

Main thing was to drill a hole at the end of the crack, this stops it from carrying on. Bit of fiberglass, filler, flatting back, paint and as good as new!!

:smile1::smile1::smile1:

[dida4g]

I got shot down on one of the forums (not this one) for suggesting the guy got his slightly damaged bumper, (just a crack), back from the repairers and fiberglassed it back up.

On the tv programme where they buy 2nd hand cars, do them up and flog them, the mechanic guy even showed you how to do it.

Main thing was to drill a hole at the end of the crack, this stops it from carrying on. Bit of fiberglass, filler, flatting back, paint and as good as new!!

:smile1::smile1::smile1:

Wheeler dealers, I saw that episode.

[andys1981]

a thought it was wrecks to ritches,that was quite a good show aswell

[dida4g]

Looking forward to seeing how the bumper comes out.


Had a day off so I went to see my Bodywork guy.
From this,
https://i.imgur.com/YTJG4IE.jpg

to this.
https://i.imgur.com/6NEIiG5.jpg


Heat gun/heater on the area to be joined,
soldering iron to fuse it together,
mesh strips heated on the rear for extra strength.

Just needs a bit of filler, paint and a new bumper grill.:happy2:

[peterzs]

Looks a good job, always thought it was a waste to dump a bumper that was just cracked.

[andys1981]

top suff mate,your getting there

[dida4g]

My bonnet arrived last week, £20, needs a bit of work but interestingly the engine bay colour matches the bonnet.
Yes I do have the MK2 grill, makes no sense to fit it yet.

https://i.imgur.com/oLwchdK.jpg

By chance I did a vehicle check with the No. plate given on the car, previous owner had transferred it, good job I hadn't gone for a MOT, I would have been a bit cheesed off.

[Stephen]

Your new bonnet colour is Copperleaf Red ( Rover 45 Colour ). Your under bonet is un-laqured Firefrost, They do both look similar.

But great work! :)

[MG ZS STE]

i quite like the old rover 400 style grill on it, bit of chrome really blings it up.

[Stephen]

i quite like the old rover 400 style grill on it, bit of chrome really blings it up.

Its a 45 one ;)

400 was incorporated into the bumper

[dida4g]

I now have a rear electric window kit.
A mate of mine is breaking his 5door civic vti.
Running gear has been sold however the rear doors are no use to Honda owners unless they're replacing accident damage.
So £20 later I have the kit, spare glass and spare rear door handles when they break.
Many of these cars are broken and scrapped on HONDA forums and Ebay with the doors on, please don't pay too much.

[dida4g]

Woohoo, I now have electric windows.

[dida4g]

Had to get the MG transported to DVLA for them to do a chassis/engine No. check, they rung me the next day with my Reg No. Woohoo.
Ordered a set of plates of ebay for less than a £10 delivered.

Brakes had surface rust on them as it's been stood so gave them a clean up as well as the caliper sliders especially the O/S rear 1 was a bit stiff.
MOT was a pass with advisory on Trailing arm bushes.

Booked in with my bodywork guy 2nd week in May for Bonnet and front bumper painting.


https://i.imgur.com/JQHkQ7b.jpg

Lexus rear lights are gone stuck em on Ebay, 'buy it now' ?30, this was after I won a set of R45 for 99p each.:yes:

Next job will be sill covers off for rust prevention.


So......I got to drive it to the MOT station, and bearing in mind I've had 2 R400 SDi's which were standard boost with decat, all I can say it was much much faster.

[peterzs]

Glad it got through everything with no probs. car looks OK as is.

Dervs do go well!!!

:laugh::laugh::laugh:

[jamesc777]

looking good matey, where about in hudds are u, im new mill area.

[andys1981]

well done kev,youve done well with this mate!

[dida4g]

looking good matey, where about in hudds are u, im new mill area.
I'm in Dalton.

[skyblueads]

Nice work, lovely colour...

[dida4g]

Sun was shining so I got out the decent camera, Bonnet and bumper still to be painted and I need a driver side headlight.
Paying £130 for 12 months road tax feels really nice.:D
https://i.imgur.com/T6tidZk.jpg
https://i.imgur.com/xWxMtV1.jpg
https://i.imgur.com/ujCrV9g.jpg

[peterzs]

Car looks good as new, like the colour.

[caled]

Looking good.

How much it setting you back to get the bonnet sprayed?

[dida4g]

Looking good.

How much it setting you back to get the bonnet sprayed?

Not sure yet TBH, he'll look after me though.
It's gonna be Bonnet, grill, bumper and 4 civic door handles for when they break.

[dida4g]

ZS going to the bodyshop today...woohoo.

Usually when you buy an accident damage car the service history can get lost between previous owner and insurance storge, however as the previous owner had bought it brand new I took a chance and wrote to her just to see if she could give me an idea of the service history, I included photo's before and after the damage. She rung me a day later to tell me she'd kept everything, all receipts inc. the service book with FULL SERVICE HISTORY.
She also said "oh, by the way, I had it remapped, it's running about 135BHP, it's had a recent clutch and the belts were done about 20K miles ago"
With that kind of info it was only right to drive the 50miles to collect it.:smile1:

[Craig]

ZS going to the bodyshop today...woohoo.

Usually when you buy an accident damage car the service history can get lost between previous owner and insurance storge, however as the previous owner had bought it brand new I took a chance and wrote to her just to see if she could give me an idea of the service history, I included photo's before and after the damage. She rung me a day later to tell me she'd kept everything, all receipts inc. the service book with FULL SERVICE HISTORY.
She also said "oh, by the way, I had it remapped, it's running about 135BHP, it's had a recent clutch and the belts were done about 20K miles ago"
With that kind of info it was only right to drive the 50miles to collect it.:smile1:

Result! Nice one mate!

[peterzs]

Bet she was pleased its up and running again.

Good result, well worth the letter.

:smile1::smile1::smile1:

[stamford]

Nice one, not many people try and contact the previous owners. Bet you are glad you did now.

[leezs110]

Great to see that this has been put back on the road & looking good as new! :)


Result with the service history & bonus about the remap! ;)

[dida4g]

Woohoo, I now have electric windows.
Just realised I didn't post this pic of the rear electric window switches and the coverup job of the old winders, basically I glued the old silver part of the winder with self adhesive black felt.

https://i.imgur.com/8awsXwi.jpg

So here we are at the end of this repair project,
Total spend as follows.
Car £580
Transport £130 (inc DVLA visit)
Rad+Fans+condensor+Airbox £60
Bonnet £35
Electric rear window kit and 4 civic door handles £25
R400 rear lights £2
parcel shelf £10
2 part worn tyres £60
Headlight glue £10
O/S headlight £58
New No. plates £10
Mot £40
bonnet & bumper repaired and painted £200

£1220 not inc road tax.
and minus £30 for the Lexus lights.

https://i.imgur.com/kZAgwxz.jpg

I've been very very lucky with this car, despite the damage it is a 1 owner with FSH.

Big thanks to this forum, many hours of great reading.
:thankyou:

[Dan1971]

Good effort pal ... Love seeing guys get hold of something for pennies and turn it into a great looking car with a bit of time and effort. Well done.

[peterzs]

Bargain of the year, glad it all turned out OK, bonus with the full s/h and mods carried out.

[daytona365]

Great job.............With a bit of TLC and patience, we can keep the Zeds on the road......

[Boot Hill Bandit]

Awesome read! Well done for saving it from being cubed and turned into the next household appliance :punk: got to say, I much prefer staring at a ZS than a new fridge freezer, even if there is food in it! :laugh:

[dida4g]

Cheers matey.

[dida4g]

:clap:12 months MOT, Happy Days

[peterzs]

Well done, 12 months fun.

:smile1::smile1::smile1:

[dida4g]

So as some of you'll know the cambelt snapped.
http://www.themgzs.co.uk/vb/showthread.php?t=21440

I've picked up a used one with 75K on it from a retired Rover mechanic. Had a few days off so I helped getting it swapped.
Monday was getting it out day.
Tuesday was swapping stuff over and all new belts, Clutch and gave the gearbox arm thing a good clean.
We finished the day with it back in the car and shafts back in.
Today(Wed) is build it back up an fire it up.

Haynes says remove fuel pump fuse and crank it till oil light goes out.
F3 and or F10 fuse.
Is this correct?

[dida4g]

I'm back on the road, Woohoo.

A few issues, I've got an engine light on an the engine is a little noisier throught the rev range than the old one but runs fine, and It also doesn't seem to rev like it used to.
It has a new manifold gasket too.

Good news is no leaks, the heater is good too.

[grimmy]

I'm back on the road, Woohoo.

A few issues, I've got an engine light on an the engine is a little noisier throught the rev range than the old one but runs fine, and It also doesn't seem to rev like it used to.
It has a new manifold gasket too.

Good news is no leaks, the heater is good too.

Happy days,guess you will sort the niggles out soon enough.

[dida4g]

The LOUDNESS has gone, I hadn't plugged inj. No1 back in.
It now revs as it used to but still have engine light on. 99% happy though.

[ZS]

The LOUDNESS has gone, I hadn't plugged inj. No1 back in.
It now revs as it used to but still have engine light on. 99% happy though.

Do you know what the code is thats causing the engine light to be on? - I have a code reader if your this way at all... lol :)

[dida4g]

I'm in Huddersfield, West Yorkshire. ( can't seem to edit my location)

No idea on the code.
Any decent code readers on Ebay?

[dida4g]

Just been to get a reset from my MOT guy, has a SnapOn version only charges £30 too.

Happy days again.

[dida4g]

Done a few jobs on this recently, removed the towbar as I'll never use it. Got 2 of those bumper crumple zone thingys for a £5 from the scrappers.
Changed the pipe from the turbo to the air filter as the other had a split, I'll give it a fibreglass repair and keep it as a spare.
Fitted my 282mm front brakes I had from my old civic along with braided hoses. The carriers needed a little TRIMMING for my Streetwise wheels, all is well though, bigger brakes are very good.

[Noobrider]

Glad your all sorted, one of the nicest colours too. Looks great

[dida4g]

The gift that keeps on giving.

Gave the rear brakes a service and fitted rear Goodridge brake lines.
Noticed I was getting a knocking noise from the front, new droplinks fitted, no more noise. While doing that job, lots of grease in view, CV boots split both sides, Got my mechanic to do that on ramps.
Last but not least Heater motor packed in, damm near removed every bolt behind the glove box only to realise it has 3 bolts and drops straight out.
All sorted now though.

[petet16]

lol, yeah the heater motor is the 3 bolts in a circle on the bottom of the heater box.

I replaced a split cv gaiter the other day, I noticed it while fitting poly bushes to the arb links and mounts.

[dida4g]

Fresh MOT, woohoo. Advisory on n/s rear caliper.

[peterzs]

Good going, always a relief when they get through.

:beer::beer::beer: :smile2::smile2:

[Rikki55]

Good read this thread! :D top work on getting the old girl fixed and still using it! Sounds like your getting every pennies worth out of the car :)

[dida4g]

Fitted front ARB bushes as the knocking noise came back.
Sprayed my winter wheels I was trying to sell, I did it on bank holiday Monday, it was a hot day so they dried really nice. 5 cans from the £1 shop.

https://i.imgur.com/j4AYgCB.jpg

[peterzs]

Look good.

I did a spare wheel, OK till I tried to put the clear lacquer top coat on, horrid mess, but its only for a spare!!!

:smile1::smile1::smile1:

[dida4g]

Couple of jobs I finaaly got round to doing.
Rear parking sensors.
https://i.imgur.com/tKxrevd.jpg


New front bumper as I broke my repaired one towing it to the garage last year.
LED D.R.L on a MK1 front fog light switch so it looks factory-ish.
Also painted the front fogs yellow with glass paint forom hobbycraft.
https://i.imgur.com/1IQlP9G.jpg

[dida4g]

Won some cloudy headlights for £21 in Aug.
Took them to my bodyshop guy in the hope of a polish up, tells me he has a new method.
800 wet and dry, then laquer on top.
https://i.imgur.com/mimSBEl.jpg
https://i.imgur.com/Tj8eiMy.jpg

I fitted them on Friday.

[petet16]

They look good, but I'd be concerned about how durable a lacquer is going to be on them.

[dida4g]

12 months MOT, woohoo.
2 advisorys, minor corrosion on a rear brake pipe and leaking water pump which got sorted the same day.
Happy days.

[andys1981]

they lights have come up really well

[peterzs]

Like new lights.

Wish I was braver!!!

:clap::clap::clap::clap:

[talkingcars]

Lights look good, well done with the MOT.

They look good, but I'd be concerned about how durable a lacquer is going to be on them.

O/E from the factory they have lacquer to prevent U/V discouloration.
If one sorts them out one should re-lacquer.

[petet16]

I know, I sanded it off a pair of lights to refurbish, not a boring job in the slightest.

[dida4g]

Changed a n/s rear caliper yesterday, totally siezed.
Glad in a way, it was the type where you mount the pad in the caliper
12 months MOT.
No advisories.
Woohoo.

[dida4g]

Just got new front discs (eBay no. 191356879173) good price I thought, with Ferrodo pads for my civic calipers, part no.1505.

[dida4g]

12 months MOT again.
This car just keeps going on and on.

[Dan1971]

Good news ....

[dida4g]

After 5 years of being my boost gauge being sat in my shed I finally got around to fitting it.
A bit gutted though its already running 19psi, never mind.




https://i.imgur.com/1N2GdVL.jpg

[peterzs]

looks good.

:):):)

[dida4g]

New 760cc Exide battery at Xmas and starter motor repair kit fitted last month.
12 months MOT again, no advisorys.

[dida4g]

Cheers PHOTOBUCKET.😬

Just a little update on my ZS.
Around March this year I started to get a EGR fault code, cleared it with the Torque App but would come back once a week or so. Ordered new gaskets, took it off for a clean, long overdue as it was shut solid. Back on the car, midrange pull is much improved.
About a month ago I started getting a fault code for MAF sensor, I did the unplug method, power came back. So a Maf-less £150 remap would be the order of the day except I took a chance on a used £15 Bosch MAF from a R25.

Well......all I can say is, this car is BACK, 4th gear is just awesome, it now pulls from 1200 RPM with ease, the Turbo kick at 2200 is largely unnoticeable as the car moves a hell of a lot quicker from lower revs.
The previous owner had it remapped but it never ever drove like this.

[peterzs]

Do go well when its all working as it should.

:):):)

[dida4g]

My thread is now Photobucket free.

[talkingcars]

My thread is now Photobucket free.

Nice one, where are the photos now?

[dida4g]

Photos on Imgur.

Now with all this extra power my minor coolant problem got major.
I got a new cap a few years ago but I was still loosing coolant, so I used plumbers tape on the tank threads with the new cap, seemed ok. Found a 2nd hand tank and cap on ebay, fitted it, no leaks, happy days.
A week later, radiator is bulging at the sides and leaking, I thought nothing of it, 2nd hand radiator lasted 6 years, got another in the shed. Fitted that, drove 23miles to work, checking for leaks, this Rad is bulging too, I'm thinking, is it the head gasket?
I fitted a new thermostat and seal I had which meant remove oil cooler, built it all back up, the oil cooler is now leaking.
EBay £30 later, fit 2nd hand oil cooler, build it all back up, drive to work got halfway there and radiator leaking.
eBay £22 later, fit 2nd hand Radiator fill with coolant however this time I reused the new cap, it was only then I realized the underside of the caps were different, the one on it had a white dome piece, the new cap fit the tank better too.

In a nutshell my MG has really tested my patience these past few weeks.
(It almost had a for sale sign on it)
I've driven it 60+ miles and it hasn't lost a drop of coolant so fingers crossed.

[Lukeus101]

Keeping the fingers crossed mate :)

[p_b82]

fingers crossed indeed... I feel your coolant woes!

given that exhaust gas -> coolant is the likely HG failure method on the L-series it could be worth keeping an eye on the colour of your coolant.... if it starts to get dark and murky, it is probably the HG.....

I drove mine 10k miles with it compromised - so if it is, it is thankfully not "urgent" as long as you keep the coolant levels at the right points!

If you noticed that your engine is running louder/lumpier it could be the timing solenoid is failing, I know that can give the car too much advance and ultimately result in HGF even on standard tune without any mods....

[talkingcars]

I treat header tank caps as a service item.

[dida4g]

I've ordered a new cap from DMGRS because coolant has been trying to escape. It happened going up a minor ish hill in 5th, temp shot up to 107c, heaters went cold. Got to a flat road, temp dropped, heaters came back.
My car is not liking any LOAD whatsoever so I thought I'll turn the boost down from 19psi. I've rotated the actuator 360 degrees, took it for a spin.
Auto Meter guage and elm327/Torque App both say high 18psi, once I got it to 19.2.
I'm going to knock it back again 180 degrees later and see how it goes.

[dida4g]

I'm in Club 200.

Woohoo.

[Dan1971]

Bravo .... :bow:

[dida4g]

12 months MOT Again.
Woohoo.

[dida4g]

12 months MOT woohoo.

However, this will be my last MOT on this car.
She's been a great car and it'll be a sad day when she goes.

[p_b82]

why no more MOT's - what you going to get instead?

[dida4g]

FREE STUFF for ZS.


Halfords roof rack also fits r45, r400 and mbCIVIC.
Mk2 headlights.
Diesel aux pulley.

Pick up only in Huddersfield, West Yorkshire.
Email me dida4g.kj@gmail.com with your No. and I'll text you back.