Work Has Started...

**PaulZX** · Wednesday 22nd April 2009, 02:19

I'm not gonna book that until I've got her running, too much like tempting fate that is....

I'll have her running by friday if all goes well, and I'll be speaking to mick that afternoon, if that's the case. It deffo won't be before 4th may, that's as much as I know for certain now. lol

**PaulZX** · Thursday 23rd April 2009, 15:57

looks like I've gotta get the grinder out to split the exhaust system... the bolts on the centre clamp are rusted to death, even putting a socket on is impossible, they're just fallin apart....

what a pain in the sack.....

and the manifold wasn't the easiest to fit... 10ish bolts, and a gasket, and you can't see one of the holes you're bolting into....

*tip* zip-tie the gasket to the manifold, get three bolts in a couple of turns, and then snip the zip-ties off....

I managed to snap one of the studs,

but there was still some threads poking out, so I got a nut on it, fully wound nicely.... I'm just stuck with these damm zorst clamp bolts.....

**PaulZX** · Thursday 23rd April 2009, 16:21

simple fix.... cut the damm clamp off with a grinder....

One on order for tomorrow morning from Cov Volvo for £9.14 inc new bolts...

**p fandango** · Thursday 23rd April 2009, 16:50

Originally Posted by TheFlyingFridgeMover

simple fix.... cut the damm clamp off with a grinder....

One on order for tomorrow morning from Cov Volvo for £9.14 inc new bolts...

you trying to run it in because you know my grinders broke or what lol

did your other bits turn up

**PaulZX** · Thursday 23rd April 2009, 16:59

yeah but there were bits wrong, they bodged together two pipes coz they didn't have the right one in stock, and missed one off completely.

they can't get one of them but I think I've figured a way round that....

**siamblue** · Thursday 23rd April 2009, 17:43

Great work mate, it gives you so much satisfaction when you do it yourself and you know it is being done right with the parts you want to be fitted

i wouldn't boost it too much with the 19t on it get it remapped first, nice to see you have some decent injectors to aid fuelling, keep us posted mate,

Gary

PS My standard zorst was the same was a pig to get off, in the end i took all of the exh brackets off to get it out, then ground the clamp off.

**PaulZX** · Thursday 23rd April 2009, 17:55

I've hit a problem with the turbo.... the water and oil feed inlets are in different places to the 15g,

Problem is the water pipe that bends around the rod coming out of the actuator. On the 15g it screws in there, but that hole is plugged on the new turbo, instead there is two holes on the opposite side, where the 15g has one. The pipe that bends round the actuator rod aint getting round the back of the turbo, and bolting two pipes in the same side is gonna be tough coz of the way they sit once attatched....

Is that normal on 19t's? I havn't heard anyone mentioning the re-routing of these pipes....

or is it something else......?

**PaulZX** · Thursday 23rd April 2009, 21:41

I love problem solving.

That's the only thing that's got me through today. I've been challenged at every step today. 1st thing I did was to gash my thumb with a 2" cut that should really be stitched.... that was pretty much how the rest of the day went as well....

the manifold was a pain to fit, the old downpipe's bolts were too rusted to undo, the water pipes into and out of the middle of the turbo need modifying quite a bit, the silicone pipes I ordered turned up with 1 bend missing, and another bend+reducer was out of stock, so they bodged together 2 pipes with a coupler, and sent that instead. It's the one for the bottom of the intercooler.... you know the bit, where there's no room whatsoever (about 2 1/2")... the one they sent extended 6 inches before it did a 90 degree turn...

I cut the exhaust clamp off, that's about the only thing that went according to plan, but that was a fix for a screw up as it was, so I won at losing, which sucks really.....

I'll be at volvo cov tomorrow to get the new clamp, and see if they do a shorter turbo water cooling pipe. If not, then I'll be finding a place that oill bend the pipe I've got to fit...

And then I get the downpipe out, put it next to the "new" one, and see the new one is a good 6" longer.....

It's a good job I have grey hair already.....

**Tomcat** · Friday 24th April 2009, 00:03

This is what modifying cars is all about PATIENCE!!!,lol.

**PaulZX** · Friday 24th April 2009, 12:18

Originally Posted by Tomcat

This is what modifying cars is all about PATIENCE!!!,lol.

woooo-sahhhh....wooooooooooo-sahhhhhhhhhhhhhh

**PaulZX** · Sunday 26th April 2009, 00:18

ok, I've solved the downpipe problem, with many thanks to Warren, and I've also fitted the 960 throttle housing, I had to make the hole in the inlet manifold a bit larger, to accomodate the larger butterfly, but that was a doddle, so no probs there.

I'm still struggling to get the right turbo coolant pipe, but the guy at coventry vovlo seems to be on the case, so it's lookin not too bad that end....

I could really do with a part number though......

**siamblue** · Sunday 26th April 2009, 00:21

Sod guessing at the right pipe just get a braided hose made up,

Gary

**Alan M** · Sunday 26th April 2009, 10:41

Ask Rufe if he can help with some 2001 on 16t or 19t coolant pipework as they are in the same positions.

**PaulZX** · Monday 4th May 2009, 18:34

...almost there now, 15 bolts, 2 clamps, 1 plug and a battery to connect.... Today, I tightened the turbo up, fitted the two coolant pipes and the oil return pipe from the turbo, fitted the standard airbox, the engine cover, the top intercooler pipe, and got her ready for abot half an hour's work away from complettion.

I'm gonna get the coolant pipe made up by a company near me, the downpipe will be here tomorrow, and the throttle housing gasket will be at coventry volvo in the morning.... In theory, I could have her running tomorrow afternoon..... I'm thinking wednesday, to be fair, with a Saturday visit to Mick at high tech for a diagnostic set up on the rollers....

D-Day is appraoaching now.... I've cheered up no-end today....

**p fandango** · Monday 4th May 2009, 18:48

Originally Posted by TheFlyingFridgeMover

fitted the standard airbox

I'm gonna get the coolant pipe made up by a company near me, the downpipe will be here tomorrow, and the throttle housing gasket will be at coventry volvo in the morning.... In theory, I could have her running tomorrow afternoon..... I'm thinking wednesday, to be fair, with a Saturday visit to Mick at high tech for a diagnostic set up on the rollers....

you got all the bends sorting in the end for the bottom IC pipe then?

glad its all nearly sorted really mate, bring on the Jap 5hite lol

**PaulZX** · Monday 4th May 2009, 19:24

Originally Posted by p fandango

you got all the bends sorting in the end for the bottom IC pipe then?

glad its all nearly sorted really mate, bring on the Jap 5hite lol

I'm swapping the escort for a 2001 hyundai coupe, then floggin that and getting a zorst and air filter... dude, it's like I'm playing need for speed here.... I love my life...

oh and bottom I/c pipe is sorted as soonas the gasket for the throttle housing turns up tomorrow...

I'm that gasket, one downpipe, and one water coolant pipe for turbo missing, and it's job done.......

**V70Stu** · Wednesday 6th May 2009, 22:59

Originally Posted by TheFlyingFridgeMover

...almost there now, 15 bolts, 2 clamps, 1 plug and a battery to connect.... Today, I tightened the turbo up, fitted the two coolant pipes and the oil return pipe from the turbo, fitted the standard airbox, the engine cover, the top intercooler pipe, and got her ready for abot half an hour's work away from complettion.

I'm gonna get the coolant pipe made up by a company near me, the downpipe will be here tomorrow, and the throttle housing gasket will be at coventry volvo in the morning.... In theory, I could have her running tomorrow afternoon..... I'm thinking wednesday, to be fair, with a Saturday visit to Mick at high tech for a diagnostic set up on the rollers....

D-Day is appraoaching now.... I've cheered up no-end today....

Are you booked in for Saturday then??

**PaulZX** · Wednesday 6th May 2009, 23:26

I'm ringin mick tomorrow morning, and I'll be in the first spare slot he has....

As soon as I know, I'll post it up here...

**PaulZX** · Thursday 7th May 2009, 11:24

Booked in at hightech for 9am tuesday, they've got 2 other slots in the next two weeks, solid booked other than that.....

Like I said before, if anyone wants to pop along, and have a laugh at my expense as mick tinkers with the fridge mover, then brin black tea, 2 sugars, and a bacon roll, ta very much... (with brown sauce)