Right, spent a few hours on the ZS over the last two days so i think a little update is in order with some pics.
Ok, so boost pipes are sorted, not all clipped up yet... but they go to the right places !
Basically, i cut a Ti pipe from the turbo to intercooler, rotated it to get the correct angle for the diesel cooler and fitted a joiner, this works well.
Then i used a diesel intercooler to tbh pipe, put a 45 degree alloy bend in it, and fitted it to a cut 620ti reducer, i may mod this to make it slightly better in the future, but it works as is for the minute.
Next, a couple of issues with using a full 420 gsi loom !
The headlights on the 400 have 2x plugs, 4 wires for main,dip,sides and an earth, also a live and earth for the indicators, the ZS on the other hand has a straight 6 pin plug, quite honestly you dont have to be a rocket scientist to work it out !
Having a multimeter makes life extremely simple !
So i got my headlights fitted
The other thing i had to do was wire up the cooling fan, on the 400, the fan is behind the rad, so only the wires for the condenser fan fit correctly, so i had to extend the wires to the front for the cooling fan, and im pleased with the result !
... hmm, didnt take many pics of that... but its x2 wires and easy, but its all taped up and routed correctly now, and pulling the cts triggers both fans now so im happy
Anyway, so with lights and fans sorted, i wandered what to do today.
Well while on multiplugs, the other one that's different is the wiper motor, this was easy as all the wire colours matched.
Again, its all taped up and fitted now, for reference i have used crimp connectors with heat shrink ends, these make a good easy connection and are water proof when the ends are warmed and shrunk down, not perfect pretty but will do the job well.
Ok, so after that i thought i would have a stab at the clutch system, i wanted to use the Ti stuff, simply because the OE ZS stuff is a bit poor !
So the master was first, i had to shorten the rod and tap some more thread on it, but again... the result is well worth it, its spot on, i even replaced the seals in it as i bought them ages ago as i had noticed it weeping.
The difference is obvious.
So threads cut.
This shows the extra thread that i had to saw off !
Replaced the seals.
Then i fitted it, as i said, spot on
The reservoir is a slight... dare i say it... BODGE !
Only in as much as i had to bend the bracket and only fit it with only one bolt.. but its the only suitable ready made mount point, and its nice and secure so im happy enough.
I then fitted the slave (this is almost new anyway, i only fitted it a month before V79 came off the road.
The run in between is a pain, as the the pipe is a larger diameter than i thought... but Ptomo is ahead of me with a nice braided flexi pipe... so i intend to copy him
will have to speak to grant at GBE...
I got bored with that and started looking at the exhaust !
I have a crappy old Ti downpipe, its way too long.
But im please to say, i chopped out the blowing flexi, and its perfect !
Just need a good BMW/VW style clamp and it will be a perfect fit, the 180 already has a flexi on the cat, so i shall use that.
Old bit of exhaust chopped out.
And resulting short downpipe awaiting a good clamp.
And thats it for now, still lots to do but i am getting there slowly !
Oh, it also appears the ZS 180 gear linkage fits ! i have the 400 one too, but i think they are the same.
Anyway, a few days chilling now, cooling system is a big must now... and the top hose will be a pain as (yet again) the AC is in the way..
Cheers.
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