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ZS TD project
Hi all, thought I'd share with you guys.
You may have seen my threads over on .org where there is a big diesel community but figured although its not a v6 or yellow some of you may still appreciate it. So, Ive had my current ZS for three years now and over that time its evolved into something pretty unique I think. Ill just talk about the latest episode of modifaction here... I took it off the road in Feb this year and got an awesome little clio 172 to drive round in while the ZS was under way. The Clio was sold at the end of summer and the ZS is now back on the road and better than ever. I do miss the Clio and would suggest that if you havnt tried one to do so at some point. Anyway, back to the MG... All this was brought about because back in February when I took it off the road the standard clutch couldn't cope with the torque from the VNT (didnt help that the release arm had seized), one of the exhaust valve seals began to leak so it was burning oil and I had an LSD gearbox to fit along with a CG stage three clutch from dark ice designs. It was originally the plan just to do the work described above but being a perfectionist I went a whole lot further as the following pictures show... |
Genuine new goodness, oil seals and head bolts
http://i276.photobucket.com/albums/k...psc2da6755.jpg http://i276.photobucket.com/albums/k...psac9963d6.jpg Had to modify my valve remover as the L has a deep head: http://i276.photobucket.com/albums/k...pscd44a05a.jpg http://i276.photobucket.com/albums/k...ps0f9cbd35.jpg Going back together http://i276.photobucket.com/albums/k...ps93a0bf35.jpg http://i276.photobucket.com/albums/k...psc4a9109a.jpg http://i276.photobucket.com/albums/k...ps44bf61ec.jpg http://i276.photobucket.com/albums/k...ps00b5dafb.jpg Shiney :D http://i276.photobucket.com/albums/k...ps56c76491.jpg http://i276.photobucket.com/albums/k...ps2bc22c42.jpg http://i276.photobucket.com/albums/k...ps021bf165.jpg http://i276.photobucket.com/albums/k...ps30bfb53c.jpg New HG, only the best... http://i276.photobucket.com/albums/k...ps7121a4a3.jpg http://i276.photobucket.com/albums/k...ps90c48a9e.jpg New vs old head bolts. Old ones were still good but wanted everything spot on: http://i276.photobucket.com/albums/k...psac9ff1db.jpg Working 8 till late... http://i276.photobucket.com/albums/k...psb5c8ac98.jpg Belts back on http://i276.photobucket.com/albums/k...pse1a997ad.jpg Inectors primed and hoses back on http://i276.photobucket.com/albums/k...psa0e356c6.jpg Why have mild? http://i276.photobucket.com/albums/k...psee04d87f.jpg When you can have stainless: http://i276.photobucket.com/albums/k...psafc95558.jpg New leak off pipe of course http://i276.photobucket.com/albums/k...ps5c27a73b.jpg New glow plugs, Bosch http://i276.photobucket.com/albums/k...ps8a05f935.jpg |
Other new stuff:
http://i276.photobucket.com/albums/k...ps4afc53a6.jpg http://i276.photobucket.com/albums/k...pseb532de9.jpg http://i276.photobucket.com/albums/k...ps7e524b91.jpg http://i276.photobucket.com/albums/k...psc4740e19.jpg Next on the to do list was the gearbox and clutch: CG stage 3... http://i276.photobucket.com/albums/k...ps1ec0d30e.jpg http://i276.photobucket.com/albums/k...ps36c72bb3.jpg Old vs New http://i276.photobucket.com/albums/k...psf754218d.jpg http://i276.photobucket.com/albums/k...psa86922b2.jpg Gearbox old vs new, new one is steel caged and has Torsen type B LSD as the pict show: http://i276.photobucket.com/albums/k...ps5eed1ef7.jpg http://i276.photobucket.com/albums/k...psaad2cfe1.jpg After a good clean. It was taken from a 25 (Catteralls) so had to swop the release arms and mounts over. They took a lot of cleaning up and a lot of greasing! http://i276.photobucket.com/albums/k...ps2464841b.jpg Flywheel pre skimming http://i276.photobucket.com/albums/k...psa3342766.jpg Check out the glazing http://i276.photobucket.com/albums/k...pscbed7745.jpg And after skimming, they took out the dowels and did a great job: removing the protective film http://i276.photobucket.com/albums/k...ps40731722.jpg http://i276.photobucket.com/albums/k...ps7cf4bd02.jpg http://i276.photobucket.com/albums/k...psa32db400.jpg New tool :) http://i276.photobucket.com/albums/k...ps1c6d3c3e.jpg Ready to go http://i276.photobucket.com/albums/k...pscf33ff37.jpg made in England :) http://i276.photobucket.com/albums/k...psa0d5fa2f.jpg http://i276.photobucket.com/albums/k...ps4b256a9d.jpg Genuine new bolts with threadlock http://i276.photobucket.com/albums/k...psccb377d3.jpg http://i276.photobucket.com/albums/k...ps74156daa.jpg |
New oil seals
http://i276.photobucket.com/albums/k...ps9cc60506.jpg http://i276.photobucket.com/albums/k...ps2fb76786.jpg Short shifter: http://i276.photobucket.com/albums/k...pse3790489.jpg New roll pin and polybushed http://i276.photobucket.com/albums/k...psad75600d.jpg MTF94 http://i276.photobucket.com/albums/k...ps84304e91.jpg http://i276.photobucket.com/albums/k...psef1282e5.jpg |
Now onto that all important turbo, there have been some big changes with this but still the same turbo GT1852V.
First of all I wittled down from two adaptor plates to one so it sits higher and is neater: http://i276.photobucket.com/albums/k...l/IMAG0092.jpg http://i276.photobucket.com/albums/k...l/IMAG0093.jpg http://i276.photobucket.com/albums/k...l/IMAG0104.jpg The next big change was to the manifold. I am running an external wastegate as well as the electronic vane control: How the EGR port started: http://i276.photobucket.com/albums/k...ps7c4b12a6.jpg http://i276.photobucket.com/albums/k...ps915fdb64.jpg http://i276.photobucket.com/albums/k...ps1b98a763.jpg http://i276.photobucket.com/albums/k...ps4087461b.jpg http://i276.photobucket.com/albums/k...ps111c5ea1.jpg http://i276.photobucket.com/albums/k...ps586521ba.jpg I then used the second of the original adaptor plates to make a plate for the wastegate to sit on and the valve seat overlapped the manifold otherwise. http://i276.photobucket.com/albums/k...ps325023ab.jpg http://i276.photobucket.com/albums/k...psc392e640.jpg http://i276.photobucket.com/albums/k...ps985c60c1.jpg http://i276.photobucket.com/albums/k...ps9f5c2259.jpg http://i276.photobucket.com/albums/k...ps38df9694.jpg Next, I wanted to clock the turbo so that the oil drain was completely vertical. Not that straight forward with a VNT as you have to rotate the whole internal mechanism the same amount as you rotate the external part. This meant re drilling and lots of measuring... http://i276.photobucket.com/albums/k...psc12d1f61.jpg http://i276.photobucket.com/albums/k...psdcc3c6e6.jpg http://i276.photobucket.com/albums/k...ps0bc77430.jpg http://i276.photobucket.com/albums/k...psfecb5528.jpg http://i276.photobucket.com/albums/k...ps1b9e0dba.jpg http://i276.photobucket.com/albums/k...psd61acd89.jpg http://i276.photobucket.com/albums/k...ps9bb28796.jpg Not so vertical http://i276.photobucket.com/albums/k...ps8df2a9fb.jpg After the above work :) http://i276.photobucket.com/albums/k...ps342a3c58.jpg |
I was now left with nowhere to put my EMP gauge tap so did this:
http://i276.photobucket.com/albums/k...ps419d21ed.jpg http://i276.photobucket.com/albums/k...psb414c7cd.jpg Custom washer http://i276.photobucket.com/albums/k...ps24f87279.jpg In place http://i276.photobucket.com/albums/k...psa8246122.jpg The downpipe was then modified for the wastegate: http://i276.photobucket.com/albums/k...ps14710caa.jpg http://i276.photobucket.com/albums/k...pseb98c0c5.jpg All together looking like a bit of a monster :) http://i276.photobucket.com/albums/k...psae69e5a0.jpg http://i276.photobucket.com/albums/k...ps65e1a377.jpg http://i276.photobucket.com/albums/k...psba17248c.jpg http://i276.photobucket.com/albums/k...psf33fe721.jpg http://i276.photobucket.com/albums/k...ps35a39651.jpg http://i276.photobucket.com/albums/k...ps8de0b15f.jpg http://i276.photobucket.com/albums/k...ps6672f2df.jpg So with all that boost I then decided I needed something more up to the job of cooling it... http://i276.photobucket.com/albums/k...psd7d2eb3e.jpg A teaser http://i276.photobucket.com/albums/k...ps2a1db570.jpg Making the brakets and fitting: http://i276.photobucket.com/albums/k...ps8f4c7bfa.jpg http://i276.photobucket.com/albums/k...ps5cfd8a13.jpg http://i276.photobucket.com/albums/k...psbeb5ac2a.jpg http://i276.photobucket.com/albums/k...psdf937490.jpg http://i276.photobucket.com/albums/k...ps170fb239.jpg The aircraft grade TV airial based top mounting http://i276.photobucket.com/albums/k...ps45a12f58.jpg http://i276.photobucket.com/albums/k...ps384c97cb.jpg http://i276.photobucket.com/albums/k...ps767d49b4.jpg http://i276.photobucket.com/albums/k...ps57428251.jpg http://i276.photobucket.com/albums/k...ps51658eb3.jpg http://i276.photobucket.com/albums/k...ps296ad81b.jpg Bits to cut out to avaid removing the air con... http://i276.photobucket.com/albums/k...ps943ec9e6.jpg http://i276.photobucket.com/albums/k...psd529bf93.jpg http://i276.photobucket.com/albums/k...ps2b589418.jpg |
Modification of the rad is required because normally the near side is supported by the original intercooler which is obviously no longer there.
http://i276.photobucket.com/albums/k...psbceb95ff.jpg http://i276.photobucket.com/albums/k...ps537522ce.jpg http://i276.photobucket.com/albums/k...ps764ec1ce.jpg http://i276.photobucket.com/albums/k...ps51c69c76.jpg A surplus bracket, recycling at its best. http://i276.photobucket.com/albums/k...pse6be35f8.jpg http://i276.photobucket.com/albums/k...psdeaa5395.jpg (It was since painted with basically every other braket in the engine bay) http://i276.photobucket.com/albums/k...ps02c6a326.jpg http://i276.photobucket.com/albums/k...ps5fef3791.jpg Satainless nuts and bolts EVERYWHERE! http://i276.photobucket.com/albums/k...pse597baf3.jpg PIPES! http://i276.photobucket.com/albums/k...psaaea6bc5.jpg http://i276.photobucket.com/albums/k...ps0a753c54.jpg http://i276.photobucket.com/albums/k...ps539af553.jpg http://i276.photobucket.com/albums/k...psc2585205.jpg http://i276.photobucket.com/albums/k...pse416b494.jpg Another nifty bracket http://i276.photobucket.com/albums/k...ps3a584391.jpg http://i276.photobucket.com/albums/k...ps114c5b80.jpg Polished ECU http://i276.photobucket.com/albums/k...psf2ac8d1a.jpg Green cotton filter http://i276.photobucket.com/albums/k...psbf1e58c8.jpg Suspension and rust proofing, never got any pics after Id cleaned up the suspension stupidly, just image they look almost new. The GAZ coilovers were another cheeky upgrade I bagged while the car was off the road. http://i276.photobucket.com/albums/k...ps691e963e.jpg Minted up rear ARB http://i276.photobucket.com/albums/k...ps51a7e798.jpg More stainless http://i276.photobucket.com/albums/k...pseea2eb98.jpg With the extra power, some extra brakes were needed. 620 TI calipers up front with 282mm discs, V6 rear brakes http://i276.photobucket.com/albums/k...ps87530383.jpg http://i276.photobucket.com/albums/k...ps8ece92d6.jpg http://i276.photobucket.com/albums/k...ps1a91e849.jpg Modifying the Ti carriers: http://i276.photobucket.com/albums/k...ps506fc649.jpg http://i276.photobucket.com/albums/k...ps51f1add4.jpg http://i276.photobucket.com/albums/k...ps13c00359.jpg http://i276.photobucket.com/albums/k...psc2ff93ff.jpg http://i276.photobucket.com/albums/k...ps1099c8c7.jpg http://i276.photobucket.com/albums/k...psca3ee168.jpg |
Old vs new
http://i276.photobucket.com/albums/k...ps9ec10389.jpg http://i276.photobucket.com/albums/k...psd179951d.jpg Those pretty brakes needed some pretty wheels to sit behind, behold the pro race 1.2s http://i276.photobucket.com/albums/k...psd964c7aa.jpg http://i276.photobucket.com/albums/k...ps33cb8510.jpg http://i276.photobucket.com/albums/k...ps32088461.jpg New Kumho tyres 40,205,17. They are the Ecsta sports, best tyres Ive ever had. Grip like nothing else! http://i276.photobucket.com/albums/k...ps188bae69.jpg http://i276.photobucket.com/albums/k...psacf9880c.jpg Back to those horrible bits of bodywork at the beginning, I finally found some skirts in the right shad of silver but the bumpers and front splitter are like hens teeth in this colour, never mind finding them in mint condition. I therefore settled on a genuine splitter in blue and had that along with the bumpers painted professionally: http://i276.photobucket.com/albums/k...psbe7ed604.jpg Off they go in the other halfs 45 TD http://i276.photobucket.com/albums/k...ps808a594e.jpg New plates http://i276.photobucket.com/albums/k...ps71453470.jpg Powder coated mesh http://i276.photobucket.com/albums/k...psa189a026.jpg Old vs new again http://i276.photobucket.com/albums/k...ps1291b7bc.jpg Bargain mats from rimmers and chrome kick plates http://i276.photobucket.com/albums/k...psae4b66a6.jpg |
So, finally, after 6 months off the road, she returns...
http://i276.photobucket.com/albums/k...psd0517ec4.jpg http://i276.photobucket.com/albums/k...ps753298bb.jpg http://i276.photobucket.com/albums/k...ps7bbec760.jpg http://i276.photobucket.com/albums/k...pse4d350eb.jpg http://i276.photobucket.com/albums/k...pscf4f0024.jpg http://i276.photobucket.com/albums/k...ps6a44ae24.jpg http://i276.photobucket.com/albums/k...ps7a7b8d16.jpg http://i276.photobucket.com/albums/k...pse41e842f.jpg http://i276.photobucket.com/albums/k...ps70c43b3d.jpg http://i276.photobucket.com/albums/k...ps7498c2d8.jpg http://i276.photobucket.com/albums/k...ps95149a1d.jpg http://i276.photobucket.com/albums/k...ps8ae74684.jpg http://i276.photobucket.com/albums/k...ps5b9f49fa.jpg http://i276.photobucket.com/albums/k...ps0f0646bd.jpg http://i276.photobucket.com/albums/k...ps12b1c570.jpg http://i276.photobucket.com/albums/k...ps1545c0de.jpg http://i276.photobucket.com/albums/k...psa3047ec9.jpg http://i276.photobucket.com/albums/k...ps530011b2.jpg And thats where Im up to, just need to get a remap sorted now on a rolling road and see what she can do. I'm off to make a brew. |
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