Just bought a 1996 Twin T Auto - Series 4 in Black.

 

Its currently got a cloth interior and a badly fitted veilside kit which I plan

to remove and sell on shortly.

 

Using my other 1991 NA i'm planning as using that as a donor car and swap

over all the goodies i like on that.

 

Let the games begin

looking great mate

Both zeds have been at the garage for two days now and I was missing them

a bit so nipped down today at my lunch to check out what was happening.

 

Turns out the previous job needed a part so work on mine got delayed again.

 

But when i got there today my old zed was out on the side and the black zed

was in the shop with the first parts removed ready for the new stat to be fitted.

 

Heres the old zed looking very lost in its multi-coloured body - Not to worry though

as it'll get a respray before moving on to a new home.

 

In the shop Gordie who's doing all the work has started his long list of jobs !

 

When I arrived he was having a bit of difficulty removing the two water pipes, all bolts

loose but the pipes had seemed to be gummed up with some sort of sealer which made

things a little trickier.

 

 

I left not long after that shot as my extended lunch was nearly over.

 

i'll post up the progress as I can get more shots.

 

The list of jobs i gave him included doing the exhaust, swapping the pollished

plennum, moving over all the shinny bling stuff over then if the suspension is

in good enough state then thats going to the new zed too.

I've had the two zeds back from the shop for a few days now and while it was there

it had a new water stat installed, water pipes swapped over and it also had the other

exhaust changed.

 

Today I done my first plenum pull !

 

I'm doing this as its cheaper than getting the current one pollished up and I just don't

have the patience to do it myself. I followed a few different guides but in the end just

winged it and removed the abvious before giving it a tug.

 

First off I removed the fuel filter and braided hoses and everything else ontop !

 

 

Removed the coil packs unbolted the plenum and gave her a wee tug free.

 

 

For my first plennum pull it took me less than 2 hours as I was taking my time,

this is an NA egine so i'm expecting the TT to be a little bit tougher for when

i finally switch them both over.

 

Here is the plennum finnaly off

 

 

I'll give the TT plenum removal a bash tomorrow !

Right !

 

Totally gave up on the black zed the other night as no matter how much I tried

the Plenum just refused to move. However I calmed down after all my

frustration and gave it another shot and this time --

 

SUCCESS !!

 

It finally came free, well after some wd40 and mr stanley it did.

 

Not the best of pics but here's the beast hidden below :

 

{ you can see my shoe string holding down the bonnet so that its not flapping in the wind ! }

 

 

And heres both the pollished plenum and current plenum sitting on my bench

ready for some cleanup work to commense at the weekend !

 

 

Still to do a water bypass and remove all those pipes on the plenum.

 

A weekend job for it - just hope the weather holds out !

I'm impressed, I've been putting off doing mine as I'm still not sure where to get some rubber tubing from to replace any if i ruin them getting it off. but as my car now has a water leak i may as well do this job, might even find where I'm getting a water leak from at the rear of the engine. Where did you get your replacement pipes? and what sizes?

lol, totally skint !

 

so not bought anything yet but shrek says try z1,

also see that zcentre does alot of pipes too !

Right,

 

 

I was planning to re assemble the black zed first but i'm totally skint and need

to buy some new hoses first so today I started to work on the silver zed instead.

 

 

With both plenums off I started to clean up the underneath by removing all the

extra piping now not required when doing a water bypass, I also took both plenums

outside and gave them a good going over with the water jeti, I was amazed by how

much cleaner the TT plenum looked after I was done.

 

 

Back inside I took my trusty hair dryer and spent 30 minutes forcing air threw all

the holes to dry the interior off; to be fully sure no water was left inside I sat

the two plenums upright forced the throttle boddies open and blasted 1800w of hot

air in as I held my hand over the other holes.

 

Since the plenum was off the silver zed I thought i'd take a peek inside and see

how she looked, amazingly clean for a zed !

 

 

Been working on the black zed again today and took off all the rocker covers!

 

The plan is to get these into my local workshop carrick engineering to them

powder coated red. I'm going for the whole black / red and shiny chrome look !

 

Heres the four covers thats getting powder coated this week.

 

The wife was out today so decided to do the washing up !

 

 

A little prep work before I take the hard pipes into carrick on monday to get powder coated red !

 

Wasn't sure what to do with the other turbo pipes so best just to give them good scrub for now !

 

lol!!!!! the pics in the sink are class :bow:

Right,

 

Got the top covers and pipes back from carrick on friday !

 

Here they are all in shiny red.

 

After cleaning up the engine of the oil i reinstalled the top covers

 

Looking great i think !!

 

 

looks sweet mate :drool:

After taking of the plennum a few weeks ago i managed to break enough hoses that

could have prevented the Titanic from sinking.

 

So the plan was to replace as much as i could, first off i checked out the condition of

the current pipes and was totally amazed by what i found !

 

On inspection of one of the PCV hoses i takes a wee look inside and discovers not a

hole to the other side but instead half of a pipe cleaner jammed in there :

 

 

Can anyone explain how the car managed to run with that blocking the pipes, PM me if

you can, i would love to know !!

IIRC a pipe cleaner is used as a filter inside the hose

So it was ment to be there ?

 

Is this a mod! As the new hoses don't have that !

I think it was a mod to trap oil to stop the valve blocking, i will try and dig out the write up

Ok, I would have thought that would have restricted the flow !

I cant seem to find the write up anywhere, I was pretty sure it was the pcv valves that had this done as a mod, i know something had a pipe cleaner in it to act as a restrictor, it seems to ring a bell now that youve found one there.

Just bought myself some hard pipes !

 

Decided to get some shiny new clips too, here they are after a good scrubbin :

 

 

Theres still plenty of black goo left on from the previous install, i'm having some issues getting

the exterior stuff off.

 

Anybody any ideas, something that wont damage the silicon itself.

Today i tried a test fit of the polished plennum and found one problem !

 

After the plennum was secured part of the front of the plennum covers

the injector plug and you cant connect it properly not without plugging

it in first then placing the plennum ontop.

 

Heres the test fit :

 

 

Is there a way to split the injector cables and run them both sides of

the fuel rail under the plennum ?

Heres a shot of the wiring harness; what i would like to do is split this harness into

two branches that can go down each side of the fuel rails !

 

doing this would be neat and hide all the cables, is this safe to do ?