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Old 11-10-13, 10:57 PM   #1
ZS Phil
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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...
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Old 11-10-13, 11:06 PM   #2
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And the dissasembly began...




The piston which had been recieving oil from the leaky oil seal:


And the leaky oil seal evidence:
Normal

Leaky


Stripping the head:





Aftermath of cleaning the head and the plenum/ charge pipe


Valves, cleaned vs how they were:


Thought I might as well "lap them in". They didnt really need it but one or two were getting a tiny bit pitted so kept me busy for a few hours until they were all perfect:
Old school...

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Old 11-10-13, 11:09 PM   #3
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Genuine new goodness, oil seals and head bolts



Had to modify my valve remover as the L has a deep head:



Going back together




Shiney





New HG, only the best...



New vs old head bolts. Old ones were still good but wanted everything spot on:


Working 8 till late...


Belts back on


Inectors primed and hoses back on


Why have mild?


When you can have stainless:


New leak off pipe of course


New glow plugs, Bosch
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Old 11-10-13, 11:10 PM   #4
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Other new stuff:





Next on the to do list was the gearbox and clutch:
CG stage 3...


Old vs New



Gearbox old vs new, new one is steel caged and has Torsen type B LSD as the pict show:



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!


Flywheel pre skimming

Check out the glazing


And after skimming, they took out the dowels and did a great job:
removing the protective film




New tool

Ready to go


made in England



Genuine new bolts with threadlock

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Old 11-10-13, 11:11 PM   #5
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New oil seals



Short shifter:


New roll pin and polybushed


MTF94

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Old 11-10-13, 11:11 PM   #6
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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:




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:







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.






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...








Not so vertical


After the above work
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Old 11-10-13, 11:12 PM   #7
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I was now left with nowhere to put my EMP gauge tap so did this:



Custom washer


In place


The downpipe was then modified for the wastegate:



All together looking like a bit of a monster









So with all that boost I then decided I needed something more up to the job of cooling it...


A teaser


Making the brakets and fitting:






The aircraft grade TV airial based top mounting







Bits to cut out to avaid removing the air con...


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Old 11-10-13, 11:13 PM   #8
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Modification of the rad is required because normally the near side is supported by the original intercooler which is obviously no longer there.





A surplus bracket, recycling at its best.


(It was since painted with basically every other braket in the engine bay)



Satainless nuts and bolts EVERYWHERE!


PIPES!






Another nifty bracket



Polished ECU


Green cotton filter


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.


Minted up rear ARB

More stainless



With the extra power, some extra brakes were needed. 620 TI calipers up front with 282mm discs, V6 rear brakes




Modifying the Ti carriers:






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Old 11-10-13, 11:13 PM   #9
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Old vs new




Those pretty brakes needed some pretty wheels to sit behind, behold the pro race 1.2s




New Kumho tyres 40,205,17. They are the Ecsta sports, best tyres Ive ever had. Grip like nothing else!




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:


Off they go in the other halfs 45 TD


New plates


Powder coated mesh


Old vs new again


Bargain mats from rimmers and chrome kick plates
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Old 11-10-13, 11:22 PM   #10
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So, finally, after 6 months off the road, she returns...






































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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