[car_overhaul] Zx 16V Project Pt2, Re-Shell And Power Upgrades....

[welshpug 1,621]

Engine oot!

 

 

nearly the end for the black car

[Miles 331 1 Cars]

Why take the box off the engine? or I'm I missing something

[welshpug 1,621]

yeah, the car is on quite an angle, so trying to get the engine and box out in one go is pretty difficult as its very heavy so shifting the crane about is very hard work, dropping 40 kilos off the weight of the lump helps a lot.

 

If I jack the car up where it is it just that little bit too high with the jack pointing the wrong way it just slides sideways!

 

this is from 4.5 years ago when I swapped the original engine, same crane as it happens.

 

 

 

 

[MiniGibbo 142]

Why did you mark the clutch arm and the other one..?

[welshpug 1,621]

its a Pull clutch, therefore needs to be placed at the right angle before the box will slide on with the fork going in behind the release bearing, which is part of the Pressure plate, i.e like all standard XU10 16v and XUD9T clutches.

[MiniGibbo 142]

Aha, didn't know that.

[Miles 331 1 Cars]

Just WP making hard work for himself, Pull clutch's are a doddle

[welshpug 1,621]

hard work? only a dab of tippex

[welshpug 1,621]

More done today.

 

One engine in the back of the trusty 405, its been in here before, about 5 years ago!

 

 

 

Set the height roughly on the crane, reverse the car up to it, pop a bolt through the D-shackle

 

 

Take up the tension with a ratchet, drive the car forwards!

 

 

 

Shift it into the garage out of the way, pop the gearbox on.

 

 

Lower the car on the jack, swing+shove the engine into the bay, jack the car up enough to get the LH mounting bracket on the chassis leg.

 

 

Take the car back up with the jack, fit the LH rubber mounting, wind the crane down till the RH arm is sitting over the mounting and taking the weight of the engine, shift the crane out of the way and pop the car back on the axle stands.

 

Dropped the slam panel on out of the way.

 

 

Got the RH driveshaft in and secure, main long gear rod from the base of the stick in (its different on the RS engine to clear the cat+downpipe) fitted the gear rods, starter motor in place, PAS pump and alternator bolted on, for some reason the AUX belt sems too short, but I haven't tried the one from the black car, might be that the RFS crank pulley is larger, forgot to check this.

[welshpug 1,621]

Seeing as I need to get it rolling fairly soon, thought I'd get some suspension back on it.

 

Quite pleased with how these look after 2 years, springs are only cheapo's not the top dollar Eibach's AST use on their competition stuff, but the bodies are pretty much as they were bar one bit where they must have been scratched. (Yes they are VERY dirty...)

 

 

Got my Wishbones off too, one side is all bolted up, having lunch then cracking on with the other side shortly.

 

[welshpug 1,621]

Found that the n/s f brake pipe was also a little crusty, so did that whilst fiddling with the suspension on that corner, also got the o/s built up.

 

 

Re-taped a few bits on the loom and got it fitted and clipped in to anything available, only the ECU and anything on the inlet to go.

 

[DrSarty 90 1 Cars]

Come on Mei. Pull your finger out!

 

[welshpug 1,621]

Hi Rich, what the devil are you doing over there?

 

Car is now at the back of the house with the old shell gone, wasn't a great deal left on it, subframe struts wishbones 2x tailgates passenger door, 15 tin roof sheets a dozen brake discs a few clutches, the old dash + heater box, came to 580 kilos.

 

The ZX non aircon only used a single speed single fan, but last time I was over at a decent scrappy near Cheltenham there was a TD ZX in there, also single fan but two speed so I got the loom off it, I couldn't take the fan cowling as it had forklift damage :lol :doh but its the same as a 306 twinfan housing which I already have.

 

 

Swapped the fan over and fitted the wiring, just need the box and a relay, and a clip for the low speed resistor.

 

 

Got the radiator and the cowling in, headlamp/slam panel on.

 

 

Bolted the air box on, slowly filling that bay up with clutter!

 

 

Stroke of genius, needed to sort a few flares that the £10 heapos**te flaring tool had made a mess of, take one Sykes vice mounted Flaring tool, and a large pair of stilsons.

 

 

No more jobs to do with the inlet off, so Bolted that on to get it out of the way in the workshop

 

 

then got p**sed off with catching my overalls knees/thighs on the pointy wing ends, so fitted the bumper and lights.

 

[rockleo 1]

congratulations my friend..

nice overhaul.

post with more details than I've ever seen.

[welshpug 1,621]

Beam stripdown day, I knew this needed doing at some point and already had bearings in stock, picked a pair of shafts up from Neat Autos

 

Quite nicely finished, no branding at all on them.

 

 

felt pretty light which I don't remember them being so previously, maybe all the ones I've had before have been the smaller bore ones? I know the Febi spec is large bore, and these came out at a similar price but my local motorfactor never got back to me after I asked them to order a pair, so sod them, they might even be on the shelf for all I know :lmao

 

 

Take one beam, weighs a fair bit as is there! Fat torsion bars too, not the original 21's

 

 

Got to use part of my recent tool kit purchase.

 

 

 

Still don't know what half of these are meant to be used for!

 

 

But this one was ruddy obvious

 

Set it so I didn't have to faff remembering to measure when I re-assemble.

 

 

Pulled the dampers and torsion bars brake calipers etc off, then pulled the trailing arms out.

 

 

Left this pile of dust from one side!

 

 

So yeah, it was dead but not seized!

[welshpug 1,621]

Avert your eyes, bright shiny thing!

 

 

Got this from Rich Walker some time ago, already powdercoated and unused since.

[stef205 91 1 Cars]

Those pins look just like the ones we make.

[dave richards 26 1 Cars]

you trying to make the car match you pushbike now?

[welshpug 1,621]

Not sure what you mean? A lightweight carbonfibre thing?

[mechanicalrepairs 8]

Mei what's the part number for the Citroen version of the rear beam kit?

 

Cheers, carl

[welshpug 1,621]

C.0538

[welshpug 1,621]

Has been some time since I last touched this!

Progress finally, got the trailing arm shafts swapped at Area52 back at the end of January.



Built the beam up, can't remember now what I set the damper bolt distance to, other than it the same both sides

but then browsing my pictures I see I had the great idea to take a pic !

 

yep, 300mm, but its 23mm bars so no its not a 50mm drop





Front beam mounts are o.e peugeot, rear ones have done little mileage as they were replaced by the previous owner.

Dropped the fuel tank off fitted the front to rear brake lines, made up two from the compensators to the beam flexi's and bled up the brakes with an Eezibleed.

Sorted the two snapped seatbelt bolts by removing the captive nuts and using harness nut plates as they're the same thread.

As soon as a little welding is sorted on the outer sills at the rear the fuel tank can go back on then tidy the bodywork, fit the inlet an save up for an MOT.

Dropped a donor inlet and my Jenveys with Sandy Brown too...

Edited April 3, 2013 by welshpug

[Paul_13 212 1 Cars]

Still got your cams sat here....

Edited April 3, 2013 by Paul_13

[S@m 156]

C.0538

Tis in fact 9769y5 - 0538 is the tool number. Cost of £655.55+vat when new.

[welshpug 1,621]

I think this will do the job.







Playing around with my 50mm lens, got this one on a half second exposure.





Big thanks to Sandy Colin and Dave.