MK1 ZS Turbo & KV6 Rebuild Project

[MickUK]

Right, so here is the plan:

I now have a complete ZS180 from work (snigger!):

http://i136.photobucket.com/albums/q172/Mick820/0A4E64FC-6444-48A5-85F0-9F9FAE6A23F3-736-000000724D7E9947_zpsabca2878.jpg
http://i136.photobucket.com/albums/q172/Mick820/526B193C-8EAA-44F4-BA75-7ED2CC281D68-736-00000072464D4E5B_zps709017c8.jpg

I also have my old Ti sitting in the compound:

http://i136.photobucket.com/albums/q172/Mick820/F9A623E4-8B8C-47AF-87D1-B1BD435B0E88-9330-00000E3B5A15F899.jpg
http://i136.photobucket.com/albums/q172/Mick820/95923B4E-4D86-4F1A-A74C-B69872E33FF8-9330-00000E3B53B04ABF.jpg

So, the Turbo lump will be removed, rebuilt & then fitted to the donor ZS. The KV6 from the donor will then be rebuilt, fettled & fitted to my ZS.

I will then have a spare KV6 to play with :group:

I'm hoping the Turbo should be up & running by the middle of the summer break, as I 'll have the full use of the facilities here plus the time to complete the work. I need to source a 420 GSi now....

All progress will be updated with plenty of photos as soon as I can!

[stamford]

I now know I am in the wrong job!

[petet16]

Good project:thumbsup:

[MickUK]

If you look on the bonnet you can just make out the starter relay from my ZS that was filled with water. Cleaned it out, tested & refitted it to the donor earlier & it started on the button. it needs a few cosmetic items where it's been in the workshop for a year but mechanicly she's fine.

[Craig-ZS180]

Only slightly envious .. lol. Looks like a couple of very interesting and promising projects you have there. Look forward to seeing how it all works out :)

[StragglaSteve]

will be keeping a close eye on this, as i am also chucking a 620ti engine into my ZS ;)

[MickUK]

I've now secured the workshop for the first 2 days in half term, so on the
18th, the turbo lump will be removed. Along with that various other bits will be removed from the Ti, just in case!

Starting to collate various items. Ironically, this was delivered last week :thumbsup:

http://i136.photobucket.com/albums/q172/Mick820/15BF8935-A667-45DF-A166-34538FBC0AB1-1482-00000191DDC55632_zpsb3e435c9.jpg
http://i136.photobucket.com/albums/q172/Mick820/8D83E4CD-B1A2-49FB-ACF8-4CE58E2DB37B-1482-00000191E534D42C_zps0ee5998b.jpg

The most important item...

http://i136.photobucket.com/albums/q172/Mick820/6FDA2A27-3156-4750-BC7A-DAAACF62AF8F-1482-00000191EA322E8D_zps8022ca32.jpg

http://i136.photobucket.com/albums/q172/Mick820/669BFA62-587B-4D0F-B225-CDC992810F64-1482-00000191EEBD3664_zps362cf61a.jpg

Valve spring compressor & piston ring compressor:

http://i136.photobucket.com/albums/q172/Mick820/AFC1A501-C417-4EA0-86DC-5737884D9A2A-1482-00000191F96EC0EB_zpscff717e7.jpg

MOT coming up on the ZS so these will come in handy:

http://i136.photobucket.com/albums/q172/Mick820/2F66989B-2B30-4DC3-8030-A09BDCD0C743-1482-00000191F412B576_zpsfa698c94.jpg

Dragging the Ti out on the Monday morning so will add more pics then.

[Eddie]

I do hope you plan on increasing the power of the Ti as it would be a pointless transplant, back in 2002/3 a memeber over on XPF done lots of side by side testing with his ZS180 and a Ti and there was nothing in it not even at POD.
With a nice workshop at hand you have no reason not to give the old T16 some more beans, love the T16 to Z swaps as they seem to work so well.

[MickUK]

Right then. First stage. For those that have PM'd me asking for pics of the removal of the Ti lump, I've added quite a few!

So yesterday (Monday) we had to move a few cars as the Ti was buried.
http://i136.photobucket.com/albums/q172/Mick820/Ti002_zps903df236.jpg
http://i136.photobucket.com/albums/q172/Mick820/Ti003_zpsf8451bb4.jpg

So, wasn't too confident about starting the Ti, as it had not been turned over for well over a year. With the help of a jump pack, she fired straight away. No misfire & only a slight tap for 10 secs. Well pleased! Backed the old girl on the ramp:
http://i136.photobucket.com/albums/q172/Mick820/Thursday001_zpsa8c4ebda.jpg
http://i136.photobucket.com/albums/q172/Mick820/Thursday002_zps363c3556.jpg
I'll let the the pics do the talking. Drained all fluids. Removed the driveshafts. Downpipe. Gear linkages.
http://i136.photobucket.com/albums/q172/Mick820/Thursday042_zps9c605644.jpg
http://i136.photobucket.com/albums/q172/Mick820/Thursday045_zps15e63882.jpg
http://i136.photobucket.com/albums/q172/Mick820/Thursday044_zpsc896ec55.jpg
http://i136.photobucket.com/albums/q172/Mick820/Thursday009_zpsdff8b4dd.jpg
http://i136.photobucket.com/albums/q172/Mick820/Thursday008_zpsc2bbecab.jpg
http://i136.photobucket.com/albums/q172/Mick820/Thursday030_zpsd8d7f015.jpg
http://i136.photobucket.com/albums/q172/Mick820/Thursday029_zps83b6d7e3.jpg
http://i136.photobucket.com/albums/q172/Mick820/New005_zps3282f15c.jpg
http://i136.photobucket.com/albums/q172/Mick820/New006_zps89901970.jpg
http://i136.photobucket.com/albums/q172/Mick820/New007_zps2dee25d0.jpg
http://i136.photobucket.com/albums/q172/Mick820/New003_zps210f8234.jpg
http://i136.photobucket.com/albums/q172/Mick820/New008_zps88797eeb.jpg
http://i136.photobucket.com/albums/q172/Mick820/New009_zps612f5d95.jpg
http://i136.photobucket.com/albums/q172/Mick820/New010_zps9fd44384.jpg
http://i136.photobucket.com/albums/q172/Mick820/New011_zps2f43dd16.jpg

Loom & ECU removed. The top end was brand new just before I got the car & is in really good nick. the bottom end seems good too, can still see the honing marks on the bores. Need to get some heavy de-greaser on the sump & the wire wheel on the block ready for paint. Will keep updating as I go.

[petet16]

That's cleaned up ok, the head has had a fairly heavy skim in the past but nothing to worry about.

[Ritchy]

bing me the 635csi, and some better wheels for it as they arent meant to be on it:P

intresting work:)

[Din]

That's cleaned up ok, the head has had a fairly heavy skim in the past but nothing to worry about.

I reckon mines as bad... still fine though, you can take a fair bit off a T16 head and have no issues.

Hello btw, thanks Mick for helping get me me on here :cool2:

Nice project too !!

Will look forward seeing your approach, hopefully it will be useful for me too :smile1:

[MickUK]

No worries Dan. I have lots of questions to be answered so as I go along I will keep this thread updated!

[MickUK]

Flopped the turbo off the other day to find this:

http://i136.photobucket.com/albums/q172/Mick820/A868E24A-FCDA-43B3-A931-990A343932EB-14157-000011E818BA16B6_zpsd0f0e362.jpg

http://i136.photobucket.com/albums/q172/Mick820/51B878AD-6F83-47A9-9BE0-C7EF8548DCE9-14157-000011E81F30F045_zps1669f71f.jpg

Ran decent boost on the Ti. Just gives me an excuse to get a bigger jobby!

Not much more done at the moment, just waiting for half term to get cracking!

http://i136.photobucket.com/albums/q172/Mick820/9FD431D5-404C-476A-BFF6-9BD4BE74C843-14157-000011E8266E4A8C_zps46291a78.jpg

[petet16]

They all crack like that, I'd be more worried about the missing waste gate flap.