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mg_zt_t
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Discussion Starter · #1 ·
... Gorn and done it again! My third MG ZT-T 1.8t... an 05 Reg example with moderate mileage in dull as ditchwater bland Grey... and ugly Black Gridspoke wheels just ripe for a decent refurb in Silver...Used the A-Frame to collect it .... try as I do, can only drive one car at any one time. A-Frame work surprisingly well and no need for second pilot.

Starts and drives fine but, overheats from coolant loss after a few miles according to the helpful previous owner. Not had a chance to look at it due to poor weather and bad light. Could simply be a worn or leaking hose leading to the so called "They all do that" scenario. Maybe something else. We shall see. Even if it has a damaged Cylinder Head Gasket, I shall enjoy the investigation and repair. This poor image was taken a few minutes before dark and the hand held camera has lied about light levels... It was much darker hence shaking image effect as the auto camera exposure action held the lens open to allow extra light. Hence poor image.



I'll get some better images in due course... no sign of any sunshine at all today. My camera is showing "clocks back" tonight time already.

My son who has more cars and projects than you can shake a stick at. He queried why I should get another. I explained that in a year or three's time, these opportunities will not be there. This ZT-T 1.8t has lots of potential, but, should effective repair not be a realistic proposition, it will be useful pool of parts for the two better ZT-Ts in the family.
 

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Discussion Starter · #3 ·
Looks alright John. One of the later ones, XPG, trendy black wheels (were gridspoke an option on these? not in black of course) and the ZT's seem to hold there price better than the smaller models. Have fun. ;)
Yes Gridspokes with much scuffing. They will be removed and refurbished in Silver. I dislike Black Alloy Wheels.

The three ZT-Ts bought over the past year or so are all MKIIs and all came with Gridpsokes. Mostly with large areas of protective coatings lifted by surface corrosion so all were refurbished.

This blue ZT-T 1.8t was a p/x taken in by a local used car dealership back in the summer. Would have been destined to suffer a premature end if I had not come along. It is now my daily driver complete with its refurbished Gridspokes in Brilliant White .... which I think are ...Brilliant. Previous owner pro-advised car had the "They all do that" so called HGF. Even the dealer told me the car has that problem and sold to me on that basis.. It did not, coolant loss due to perished coolant hoses as I discovered the first time I used the ZT-T at sustained higher legal speeds :~

This is the car. I like ZT-Ts. Quite a lot about locally too so yes, they are popular. I see more ZT-Ts rather than the also popular Rover 75 Tourer locally :~

 

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Discussion Starter · #5 ·
Out of interest do these dealers call you when they get one in or do you just happen upon them?


Something like:
:idea: I've got an ZT trade-in, I'll call MG John!
Yes, it can work like that but, very occasionally. Usually once in a blue moon... :)

Good idea to visit local dealerships. Particularly now with most nice old cars worth next to nothing at auction or in scrap value. Bargains to be had if you are polite and explain what your interests are.

Some years ago, soon after I retired, I had 500 business cards printed detailing my "amateur" interests in cars and car parts.

More often than not, initial contact with local dealerships originates from cars they put on ebay or in local classifieds. Done this more than six times over the past five years or so. Three ZTs included from dealers within say a fifteen mile radius of my home. Have looked at rather more though. Always on the look out for a bargain project. Being local, best to take advantage by going to have a look before bidding. I'm usually outbid ... you can't win 'em all... :)

That blue one was only four miles away. I went along to have a look at the car the dealership had on ebay before bidding. I was handed the keys and had a good look. However, after checking the car, I spoke to the staff there and gave details of what cars are of interest to me. Left one of my cards. I told them I would bid.

I bid what I felt was a good price to allow for any HGF work needed as mentioned in the ebay description. I was outbid and so thought nothing more of it.

Checking my answerphone some days later there was a message to say the top bidder had made no further contact so if I'm still interested in the car, my lower underbid they would accept. That happened soon after agreeing on the very same morning to buy another ZT ( Saloon ) from a different local dealership. So, circumstances conspired to make me buy TWO ZTs that same day! :rolleyes:

TYPICAL.... London buses scenario... wait ages then several come along at the same time. Both were opportunities hard to refuse like this latest grey ZT-T.

Mind you, it's ages since I travelled on a Bus let alone a London One..

He who dares Rodders... :)
 

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Discussion Starter · #7 · (Edited)
Sounds like you're the real life wheeler dealer; Mike and Ed in one.! Keep it up - I'd like to do similar when I have time. Many years to go until there's any chance of retirement for me though. Until then enjoyable small projects that take ages to complete...
:bgrin2:
Be patient. Your time will come soon enough particularly if you have a demanding job which consumes most of your time which for me has flown by!

I now have some time to do the things there was no time for when I had a demanding job. I could now put my feet up and sit in front of a TV screen all day. That's not me. I have the time for these things and will continue to do so for as long as it gives me pleasure. I have no deadlines to meet. I might work on a car from dawn to dusk or not touch one for a week or two.

It's an old cliche but very true. Now retired I'm so active I wonder where I found the time to do a full time job year in year out for over fifty years.

As the MG-Rover adverts reminded us all over ten years ago, life is too short not to. It really is.

Trouble is, us Brits in our wisdom formed queues to pay over the odds for cars not built here which many soon found were not all that after all . I have worked on them for friends and relatives so I know what I'm on about. ..Then allowed the asset stripped remnants known as MG-Rover to simply die. Some posters on the car enthusiasts web sites at the time expressed delight at the final demise of Longbridge once the receivers were called in. That after a Government turned its back on the thousands of jobs related to the now almost extinct British Car and other manufacturing Industries.

Whilst I type this, I have the Andrew Marr show ( BBC1 ) on at the same time. Marr is currently asking questions about the so called "British" car Industry NOW and how to protect it after severance of the parasitical umbilical cord of EU membership. What an oxymoron! Where was this ever so clever so and so and all the other cushioned against reality media smoothies asking those very valid questions all those years ago when that was a much more timely question to ask.

It's what we do ... correction, just maybe did after June 23rd.

Over the years, I have enabled a number of nice old cars to live on and avoid an unjust premature end. They live on in friends and family member ownership and look set to do so so a good few more years yet.

It's what I do.... ;)

EDIT to add ...

My Dad was a real wheeler dealer come Del Boy Londoner. He spent his life working hard trying not to work hard... that when not dodging bombs and stuff between 1939 and 1945 in London's East End.:) Here he is about 1965 with his wheeler dealer Minivan ....



So Photo bucket no play the balls. I have a cunning plan. Here's that image now with another more user friendly image hosting site.. :~

 
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Discussion Starter · #8 · (Edited)
Talk about London Buses coming along in threes. How about this beauty?

Talking about London Buses coming along in threes. Now fours even! .. :lol:

TYPICAL! Get thee behind me ... :D

This looks an even better opportunity for me if I did not already have too much on my plate. In a more vibrant favourite colour too and not all that far away for a tow.

Turbo Temptation in vibrant Red

Must be strong and resist .... ;)
 

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Discussion Starter · #12 · (Edited)
MGJohn - My 75 is just coming up to the moon mileage and is now over 13 years old. Still used almost everyday and is just fine. These cars are worth it.

(Moon Mileage 225,000)
Who's moved the moon then? Thought it was a tad short of 250,000 miles ... on a good night... or, day come to think about it... :)

Ah but, yeah but, it has the BMW engine and not the Rover one otherwise your car would have self-destructed about five miles after leaving the showroom new. Well known fact. Been on TV and everything. Clarkson formerly at the BBC spearhead of British is rubbish, German is superior so must be kosher. They're all professionals so obviously know what they are talking about. OK, I lied about the latter. Shame on me for not believing most what those oh so clever media folks know.

Far too many over rewarded know-all know nowts on the TV and elsewhere where UK Motoring Journalists are involved with the now beyond endangered species former UK Indigenous Motor Industry is concerned... Extinction only a matter of time.

Not all, today I did something I rarely do. Bought a Motoring Magazine this month which was not Car Mechanics which I always buy each month. That other magazine being the relatively new:~ MODERN CLASSICS.

A delightful refreshing change to read a UK Car Magazine which is not always bad mouthing the products of Abingdon, Cowley and of course ... Longbridge.

Mind you, according to my "Always buys German" neighbour and the bloke I bought my Rover Turbo from, both assured me the reason all my MGs and Rovers are so powerful and reliable is because of their Honda Engines. I kid you not.

Media negativity influence John? No way. Simply does not exist. They know what they're on about ... after all they are highly paid professionals. Say it often enough and it becomes gospel. You heard it here last.

Right off to study the odds on tonight's Football. I'll back the foreign teams ... after all. The Brit teams are all losers... well known fact.

What's that hissing sound I can hear?... :hgf:

Oh, just another cylinder head gasket letting go. Only happens every week there's a day in it..

Yow heard it here last ... ;) (See what I did there... added a smidgeon of black country accent... :) )

:rofl: ... Does you good to have one occasionally ..

EDIT to Add @ 19:56

:dunno: Resist - you'll probably fall out with the neighbors if you park up another car in the street...
Yeah but, yeah but ... I have a cunning plan.

One of my properties has it's nearest neighbour a quarter of mile away. You can cut the peace with a knife... Bliss... :)

P.S.

Has Man C. scored yet?... after all they're playing some little known team of also rans... :)
 

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Discussion Starter · #14 ·
05-Reg ZT-T Project. A set back. Trashed Wheel Arch Liner and lost ABS sensor.

This Sunday afternoon was the first opportunity to have a close look at my latest project and drive it on my own personal track. Yes it's an old cliche but I have one, a small oval in a few acres which for close to thirty years I've been turning into a mini Nature Reserve. My main interest outside family and cars being Natural History. The family and friends have spent many happy hours there from camping out in high summer. Lots of interesting wildlife to observe every visit. Even today disturbed a female Buzzard as I pulled up to the gate. Even fireworks on November 5th. Not this year though ... Twenty years ago, my two sons both learned how to handle a reasonably powerful car there well before they were old enough to drive. So did many of their school friends. Here's my eldest boy in an MG Montego 2.0i enjoying himself during his schooldays.



So, although a little overgrown in places, did a few laps in the ZT-T 1.8t to get the engine up to working temperature to assess the state of the Cooling System, Cylinder Head Gasket, Brakes ( V.good ) and other things. Pleased by what I've found so far. Right last lap gave it a bit more and as I took the very last turn there was a muffled explosion like running over say a supermarket 6 Pint Plastic Milk Bottle. Something was dragging in the front nearside wheel arch as I pulled up. Amazed by what I saw. Somehow, the complete Wheel Arch Liner had been ripped out of the wheel arch, taking with it the ABS sensor cable which was more of a concern. Yes, the ABS icon now glowed brightly :doh: Damn und blast ... :) Can only assume that in previous ownership, the Liner had not been fastened correctly for whatever reason, dropped down during spirited driving and became trapped under the wheel and so ripped out immediately! All part and parcel of old car projects. Have to take things like that in my stride.

The cooling system had been overfilled in previous ownership ( No air for expansion ) and yes it boiled over a little once parked up and with no air to expand into, escaped via the cap as loosened it a little. No healthy gentle hiss as with a healthy cooling system and CHG ... so looks like I will have to remove the Cylinder Head with this one which has a damaged gasket. Here's an image showing coolant on the Air Filter Housing :~



Lucky I had my Multimeter with me and some other tools. That included a length of old ABS cable prepared with both Blue Connectors. First I took readings on my "Control" car... my 55-Plate ZT-T which provided control guidelines of an known working ABS system for comparison with the faulty items on the 05-Plate ZT-T. Here is the set up using those off cut ABS cable connections I'd prepared previously. I have them for the various car types in the family ~ just in case. Which gave this and other readings from the control car's feed supply. :~



These were the range of readings for comparison. The final reading, the resistance of the cable to the wheel sensor, produced a big fat ZERO. 0.000. Not written down as the rains came down and had to pack up and cover the tools for a while. The paper is actually wet with the rain.



So looks like the car will need a replacement front nearside ABS Sensor. Deep joy removing the old one : rolleyes:

The rapidly changing weather and brief heavy shower soon had the car fully misted up on all the inner glass surfaces. So before packing up completely, opened up all the doors to allow the cabin to become fully aired and dry ... just as the weak Sun, now low in the sky and soon to disappear behind the Hills, shone brightly. Better late than never sunshine ...:) Yer Tis :~

 

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Discussion Starter · #17 ·
Used this project for a few brief journeys just enough to warm the engine up despite often below freezing temperatures. Soon sees steam out from around the bonnet when you pull up and stop. This is what I saw when that happened. A jet of steam appearing to come from the Radiator Core or, more hopefully, from the Coolant Hose. The Fan was running at high speed so blows away the leak effectively disguising where the coolant leak is coming from. :~

View My Video

Later, with the powerful fan not operating, clearly the leak is from the short top hose attached to the T-Piece.

View My Video

So I will not need a new Radiator ... that's good news. Here's the problem. Could that be the prime reason for coolant loss in previous ownership? Loss leading to Cylinder Head Gasket damage from resultant overheating. Your guess is as good as mine but, it certainly wouldn't help.



It pays to lift car bonnets on scrapyard visits and having done so, I had a couple of good used spares including a pretty blue one. :~



I did not use that one... :) :~



Keen eyed observers will spot the OE Manufacturer's alignment Indexes on the hose are not lined up. To have correctly done so would have twist stressed that short hose... something to avoid for obvious reasons.

Very hard to spot unseen hose fatigue wear like that even by an observant car user who does lift the bonnet as all car user should do to check for pending problems. Losses of coolant at Motorway Speeds would be far more rapid because of higher coolant pressure with Motorway engine speeds. Hard to spot at engine idle speed. The previous owner obviously knew about coolant being lost but not where from. He had been topping up and when I checked the car the day I picked it up, the Coolant Expansion Bottle had been over filled to the top of the filler neck... leaving no air gap for expansion. The previous owner is a railway engineer so knows his way about a box of tools. Less so about what goes on under a car's bonnet.

There's always a reason for these things... always.

Ongoing...
 

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Discussion Starter · #18 ·
You couldn't make it up.

Not touched this car for some days now, mainly due to unsuitable weather for working outside and having caught a nasty chest and throat infection which saps the energy. Now I know how HRH Liz ( and Phil ) felt recently.

Even so and despite that, dry underfoot today and light cloud without any threat of rain. An hour or so in the fresh air will be beneficial to my health and in the past, has aided a speedier recovery. Felt good to be outside and productively active again in the fresh air.

Right, will tackle that pesky CRANKshaft Pulley Bolt. The thick wodge of Invoices that came with this car included one for £1423.26 for Cylinder Head Gasket repairs which included sub-contracted bottom end repair on the same date: 17th September 2015. No doubt power tools used and that 22mm Crankshaft Pulley Bolt will be silly tight. So it proved. By the way, masses of work done on this car since 2011 ~ lots of useful renewals if they can be believed ~ and a quick count up of the Invoice totals came to ... wait for it ..

OVER £4000 ...

That since 2011! Truly ridiculous bearing in mind the wording for some of the completed work on those invoices. Lost count of the times I've seen something like that with "problem" used cars I've bought over the years.

Any road up. Back to the task in hand, still dry under foot and got all the tools in place and the car Jacked up securely on Axle Stands and front offside wheel removed. Even used my recently arrived Knee Pads which takes a lot of the pain and strain out of kneeling when working low on cars. Then guess what. Clouds moved in swiftly a large spots of rain falling and looking set to get heavier.

Sometimes I think the whole world, nay Universe is against me. Happens far too many times with perfect timing to be mere coincidence... GRRRRRHH. . No going back now.

Using my trusty 24 Volt impact driver no way would that 22mm Crankshaft move. Not a good sign it usually copes except when power tools in previous ownership means bolts silly tight.

OK, plan B involving my heavy duty 3/4" Drive Breaker bar and extension rested on anAxle Stand for more control. Always worked without fail for me in the past as this set up did precisely that ... in the past. Like this :~

First the BIG Breaker Bar with my son's fight foot heavy on the brake pedal with car is 5th Gear. That usually cracks it.



Then socket wrench to remove it.

Not this time though and now I'm getting really wet. OK, I know when I'm beat ... Here's the working area view just before I rapidly packed the now thoroughly soaked tools away.





Thing is, I lent my son my 240volt Impact Driver and so that is over thirty miles away. That usually makes short work of even those Bolts silly tight. This one. Will PM my son asking for a speedy return :~



Meantime, about an hour ago the rain stopped with clearing blue sky and bright sunshine before it disappeared behind the Hill. The Weather Gods really rub it in sometimes... :)

Just about to press Submit Reply button with my eyes streaming, and nose and chest sore. Worse than before. Not such a good idea to get some fresh air after all.. :(
 
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Discussion Starter · #22 ·
Only just seen these... Hence tardy response ...whatever happened to notifications? About to update thread on a little progress and spotted these latest posts.

John, John, John, John, John, John, John, you just can't keep it in your trousers can you?! (Your wallet, I mean, obviously!) Still, another one saved, so well done.

How's KX54 coming along?
Haha ... so true. I can resist anything but temptation.. :D

These nicer MG ZT "project" cars have bottomed out in value now and such opportunities will not be around in a few years maybe sooner. I currently have a couple of ZTs in daily use... @ £270 pa VED ( probably go up in a few weeks :rolleyes: ) KX54 is on the back burner until I clear the decks. Just a few simple jobs to do on it but, £270 takes some finding so it's on SORN.

Will sort it when the warmer weather and lighter evenings are here. The garden daffodils are popping up and will flower soon. Love the early spring. Cheltenham Races... start of Flat Racing and Formula 1 seasons and nicer conditions to play with the cars.

Oh how I wish I could share a pint with you sometime to compare notes. Alas being at the other end of the country it will likely never happen, however here's my take on jubilee clips.

The jubilee clips are prone to collapse the unsupported plastic t-piece, because they do not grip evenly and the plastic stub soon ends up egged with heat or even worse collapses with too much pressure applied. You would be better going back to the scrappy and also collecting some of that spring type of clips which give an even clamping force. There are a few spring clips fitted to a KV6 that will fit.


This is the reason folks end up cursing the original plastic t-piece and buy an alloy t-piece instead because during the life of the car the original swaged pips clips loose their tension and start to leak, the clips also cut into the easily cut turbo hoses leading to leaks. some folks cut a little bit off and fit them with a jubilee clip only to find them leaking again. If decent spring clips and a light touch are used you will not have an issue with the plastic t-piece.

Having spent the whole weekend on sons ZS180 doing the timing belts and finding all sorts of leaks. I found the dreaded jubilee clip bodger had been at it on plastic housings too and had collapsed the pipe.

Jubliee clips work well on older cars which are mainly fitted with metal stubs but if you use them on plastic you are asking for a problem if you cant control the tightness of the jubilee clip.

Some plastic stubs have metal inserts where the jubilee clip will work fine such as the intercooler hose on the turbo models. MG Rover in their wisdom unfortunately decided to omit inner metal sleeves from the plastic connection for one reason or another to the detriment of the vehicles life if some heavy handed person sets to the car.
Haha.. you're norf of da buddr ... so that's like foreigner territory to us Southerners... :) More seriously, if you're ever in these parts and have time to pop by for a chat and a cuppa, please get in touch. Over the years I have met many MG and Rover enthusiasts and always enjoy sharing experiences about a common interest. I take pictures of the cars of every visitor. Now well over one hundred. My older son also has many young MG and Rover enthusiast friends and he often had visitors, including one from as far away as New Zealand who keeps and MG Midget here for visits. :~



Note Kiwi on the Door.... :)

================

Now to your post.

Thanks for that comprehensive reply about the hoses and clips etc..

With what you explain already in mind, I have already collected a small tub of those constant pressure hose clips from scrapyard visits. I have also bought the correct tool to compress and fit/remove them. Prior to getting that tool, I did not like the things. Now I do... old dog, new tricks myth buster... :)... and have ordered THREE Alloy 1.8t Coolant T-Pieces. Have already fitted one. So those plastic jobbies will soon be a thing of the past.

I worked on this car briefly today as the weather had improved and so did the light. Watch the next thread update on this project car I will prepare soon with illustrations. Work was slowed and delayed as I came across three heavy handed bodges. In previous ownership large Invoices were for the professional work on this car. I half anticipated this in view of how silly tight that 22mm Crankshaft Pulley Bolt was. So unnecessary ...All very sad.
 

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Discussion Starter · #23 ·
There's more ... progress update.

Not touched this car for a couple of weeks.

Bit disappointed with the little work today. Here's why.

Made a start on Cylinder Head removal which soon revealed some heavy handed treatment. Two of the 8mm Bolts which fasten the Ignition Coli Packs had been overtightened. Cue soft alloy threads destroyed. ..:( :~



and the other one too :~



Next work to remove the four Spark Plugs and with the stripped threads above in mind, I was anticipating more of the same. Plugs 1,2 and 3 came out smoothly as you would expect but Spark Plug in Cylinder No. 4 was silly tight. I had to use this Breaker Bar vigorously and carefully until it came out. :~



Here's that Spark Plug :~



There's another bodge. The HT lead held against the alloy Camshaft Cover and the Electrical Loom which should be there loosely nearby. :~



So that's three stripped threads which will need attention... Helicoil if not too far gone. Will know more when head is removed. I hope I find no more heavy handed treatment. That massive Invoice for the pro-work done on this car still fresh in my mind. :rolleyes:

However, not all bad news to report, all that possible Head Repair Work or scrap it decisions can wait. Meantime I have two K-Series Cylinder Heads refurbished on standby all ready to fit... Be prepared as the old saying goes.
 

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Discussion Starter · #25 ·
Hi John
been reading a lot of your stuff tonight, really good and interesting stuff
and I wonder if you can help me with my problem, I've been doing a CHG on my Rover 25 and now trying to install new valves, got the old ones out easily by the hammer way, I have now bought my second spring compressor to install them but none of them worked, could you recommend one that will suit the job, been of road from before Christmas as poor weather not allowing me much time to work on it, and getting some agro indoors,
HELP!
'er indoors? ... :)

Yes, accessing the valve springs with a compressor is sometimes difficult on the little K-series. I have two Compressors, one works fine on the restricted reach access of the K-Series but the other does not. I will take a picture of it sometime soon so you can see which one works and search your local Machine Mart or w.h.y. to find one to suit. It has two reversible ends which fits various valve cap sizes.

Here's a tip for you are anyone working on these cars.

By the way, if you have a local "remove it yourself" car breaker yard ( like wot I do ... :) ... ); good used Rover/MG K-Series Cylinder heads can be picked up relatively cheaply. Get one and prepare it ready to fit. Because traders no longer see these cars as "nice little earners", mainly due to trading constraints, perfectly good cars taken in part exchange are driven straight round to the breakers now. In my favourite local breakers, I removed a cylinder head from a Rover 75 1.8 turbo which according to the VOSA MoT records, had only done 39,000 miles. I also got the Turbocharger and other useful bits. They will come in handy one day ... they always do for me or someone needing parts for their cars.

Then sort out the original Head and keep as a good spare or sell it.

Helps to keep the cost of motoring down.
 

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Discussion Starter · #27 ·
Best sunshine of the year today.

Took advantage of the superb sunshine and mostly clear blue skies for three hours working on the car. Progress is slow removing the Cylinder Head due to numerous reasons, mostly beyond my control.

First I drained the coolant by releasing two of the lower Constant Pressure Clips either side of the PRT ( Pressure Relief Thermostat ) and carefully pulled the big hoses away from the PRT. Lots of dirty coolant rushed out. I used a large plant pot drip tray to collect the coolant. Then poured it carefully into a plastic container. I will not reuse it and here's why. That's not Gold Dust but traces of "snake oil" coolant additive. It most certainly would not stop the unseen small split under the short hose connected to the T-Piece.



I half suspected to see something like that as there were traces in the Coolant Expansion Bottle. I will use SPEEDFlush when repaired car is up and running. That will effectively clear any unwanted stuff from the whole cooling system including the Heater Matrix.

Next job I always not like to do. Undoing the four nut/studs which secure the Exhaust Manifold to the Exhaust Downpipe/Turbocharger. There are three upward facing studs with 13mm Nuts, these were Hex Nuts ( six sided ) but earlier cars often had Bi-Hex ( twelve points ). The fourth stud nut faces downwards and is always difficult to access and undo. This one above the Wastegate Opening Crank.



In the past, to provide better access, I have disconnected that Wastegate Actuator Rod by releasing that pesky C-Clip ... which usually springs away at Mach 1 into the Unknown. :rolleyes: Been there done that and will not need to do that today on the Hex-Nut. Will deploy ... Enter the 13mm Crow's Foot Socket ... :)



It worked perfectly ... Hoo-bleedin-Ray ... :)



The upward facing Stud Nuts were much easier to deal with once sprayed liberally with Penetrating Fluid., Again the Crow's Foot Socket helped access that one Nut shrouded by the Manifold itself.



That done, turned my attention to the top of the engine. Undone the 13mm bolt and its 15mm Nut which holds the Alternator, and now free, pushed it towards the radiator to allow access for Cylinder Head removal later. Then undid and stored all fifteen 8mm Bolts which hold the Camshaft Cover and its Gasket in place. Those lifted off easily revealing a coolant-mix free Camshaft assembly Area. Good to see that. So if there is escaping compression gasses over pressuring the Cooling System, oil does not appear going that way at all. There may not be anything wrong with the CHG. I will fit a new one anyway along with a pre-prepared Cylinder Head assembly. Here's what was revealed with cover removed :~





That allowed access to the Ten Through Bolts and all ten were undone a few turns once I had rotated both Camshafts to allow access to the two through bolts between Cylinders three an four which are usually blocked by Camshaft Sensor Half Moon Lobes which are always in the way.

Half way through this work, a near neighbour who usually finishes work early on a Friday, fired up his 6.2 Litre V8 Mercedes-Benz weekend car. Lovely noise.

Want to come for a ride John? Damn... I had to decline his kind offer as it would take best part of twenty minutes to collect up all the kit and tools and lock them away. I was promised another time.

Then used my Blue ZT-T to visit a relative nearby as my back reminded me I am no longer in my mid-thirties and it had had enough... Tomorrow's another day.. :)
 

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Discussion Starter · #28 ·
The Cylinder Head is removed at last.

In between sunshine and showers made some progress today. Still got soaked .. twice. First image shows additional leverage needed to release the seven silly tight 13mm Inlet Manifold Nuts.



Three of which were not OE Flanged Nuts but flange-less ones of poor quality. These latter corroded and so prone to rounding the flats. A few minutes job to remove which actually took over half and hour due to over-tightening and poor quality nuts used. There was more evidence of the wrong nuts and bolts today and previously when working on this engine... so unnecessary.

Another problem was removal of this Clip on the small hose which connects to the Jiggle Valve in the Inlet Manifold Stub Tube. Five minutes to carefully remove instead of a couple of seconds. The tang was broken off and missing the sharp bare end penetrated the hose material. :~



One of the attached images shows the broken Clip after removal. I have a spare and will fit that on reassembly. Removal of the Inlet Manifold revealed a very worn and perished Inlet Manifold Gasket well past its sell by date :~



Once the Cylinder Head Assembly was lifted away it revealed an Elastomer Cylinder Head Gasket had been fitted PLUS a Head Saver Shim... :~



It was fast approaching 6 p.m. and darkness and it started to rain .. my feet were nearly numb with cold so I can take a message from the weather Gods.. again .. so I called it a day... Tomorrow is another day too... ;)
 

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Premium Member
mg_zt_t
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Discussion Starter · #29 ·
A little further progress.

Keen to check liner heights, I removed the old Cylinder Head Gasket [ CHG ] ready to pressure wash all the engine and its compartment.

This was the state of the Block after removing the CHG.



I used a Syringe to suck out any remaining old coolant. :~



After the pressure wash, I was pleased with the clean engine compartment but, one negative, the protective Heat Shield jacket around the oil supply pipe to the Turbocharger had partially disintegrated. Will obtain a suitable replacement :~



I then turned my attention to the old CHG. After a quick wipe over, it was not an Elastomer as I first though but some kind of MLS of a type I did not recognise. Some sealant appears to have been used. That will need to be cleaned off the block prior to fitting my spare refurbished Cylinder Head and new Gasket.

I then ran my finger test across the four Cylinder Liner ~ Cylinder Block interfaces. I was pleased that all four passed my "finger test" confirming liners slightly proud of their surround block locations.
 

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mg_zt_t
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Discussion Starter · #30 · (Edited)
Little more progress.

Despite fitting a shelf in the kitchen and a bit of painting, found an hour late afternoon to lift the bonnet of this project car.

First I selected a new Elastomer Cylinder Head Gasket. I had one each from both ELRING and FAI. I chose the ELRING although, they looked almost identical. The guide TOP and FRONT as well as the holes and numerous other Manufacturing Tooling Marks make me suspect, the basic metal sheet came off the same manufacturing machine! Even all the Elastomer Seals appear identical. No signs of any differences except a very minor one. Around some of the "Church Window" shaped Elastomer Seals on the FAI item, there appears traces of something which I suspect is adhesive although I have no way of knowing. Those ten "Church Window" shaped holes are where the through bolts pass down to the bottom of the Cylinder Block where they locate in the Oil Rail.



Both came with impressive Instruction Guide Sheets :~



I sprayed the Block and Cylinder Liner tops with a very weak solution of Fairy Liquid.... Much <5% dilute. Then used a wire brush in my trusty Black and Decker Pistol Grip Electric Drill ( bought ca. 1972 ) very carefully and lightly to clean up the Block's top surface and Piston tops. Followed that with a light working of the cleaned area with some 180 grade wet and dry used wet. Then used Kitchen Tissue Sheets to mop up and dry away any moisture. Pleased with end product. :~



Not 100% convinced my Cylinder Liner Height "finger test" showed all four liners proud of their surrounding block locations.

This is the test I've used many times in the past. This on a 1.4 K-Series liner.



Still doubtful I slide a 1mm Feeler Gauge against the Liner. If it stops that's good enough for me. :~



Today I used trusty straight edges and feeler gauges to check and check again.



Not as clear cut on all liner-block interfaces as in the past so just maybe my using an Elastomer CHG for the very first time is the right choice. Previously with a dozen plus K-Series CHG renewals, I've used the MLS so called uprated gasket.

Then placed the ELRING Cylinder Head Gasket over the two locating dowels. :~



Large spots of rain started falling ... again! ... so packed away the few tools before they became soaked and covered the work with a piece of board to protect it. Same old, same old ... rain stopped play. Must be patient.

 

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mg_zt_t
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Discussion Starter · #32 ·
Cripes John - you even have a special board to fit over the k series block!

Hope the weather improves. If it makes you feel any better, I got wet earlier this week fitting a new rear caliper to the zs as the old one was sticking. Had to be done as the car was needed...
Lost count of the times this frustratingly boring autumn and late winter I and all my tools have got a soaking. This frustrating weather literally puts a damper on things not least my enthusiasm for the project work. Lovely bit of sunshine, get all the tools out and work area set up ready, down comes the rain from a big black cloud from nowhere...directly over me... Paranoid ... just a tad... Grrrrrrh!

Not only my special board, somewhere in the depths of my garages, there's a sheet of Alloy specially tailored to do the same as that piece of board only better and a closer more secure fit. Also another sheet of alloy as a perfect fit on a T-Series Turbo...

As the title suggests, there really is no known cure... Good eh .. :rofl:
 

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Discussion Starter · #33 ·
More good progress today. Time consuming little jobs done.

Chilly but lots of fine sunshine so made more progress this afternoon. Concentrating on the various fixings needed on the refurbished spare Cylinder Head. :~

Bare Cylinder Head :~



New Exhaust Manifold Studs and lightly refurbished Coolant Elbow. :~



Using two 13mm Spanners to lock together two 13mm Nuts so that the Inlet Manifold Studs can be extracted from the original Cylinder Head. There are seven and this took a good bit of time but, worth while.





Very time consuming but getting there :~



New Exhaust Manifold Studs and Gasket in place :~



Exhaust Manifold Bolted up :~





Fast losing good light then so I quickly assembled my small Angle Grinder with thin metal cutting disc. Then cut off the excess threads from each of the five Exhaust Manifold Studs. If ever I ~ I may keep this car ~ or anyone needs to remove those Manifold Nuts, far less undoing required and less thread to become corroded. Four of the five Nuts and Studs on the car's original Cylinder Head were seized solid. Each came out as one which helped when inspecting the old head. Working on that gave me an opportunity to have a closer look. It had been skimmed in previous ownership and appeared in good shape. I'll clean up and refurbish it in due course. Will come in handy one day. They always do.

Pleased with progress today.
 

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Discussion Starter · #34 ·
Sick and tired of frequent heavy rain showers.

Despite many rain showers over the past couple of days, made a little more progress. Frequent soakings now leave me with a very nasty chest infection and most joints aching... :rolleyes:...

First, I got a Turbo to Exhaust Manifold Steel Gasket from my box of new spares only to discover it was a T-Series Turbo item.. more :rolleyes: Fortunately I had a K-Series one too. News to me they are so different. Oval and rectangular Apertures. See here. K Series on the left :~



Correct item in place after cleaning interfaces :~



Tidy bodge repair revealed ~ does work though.. :) :~



Thin wood pieces to protect Gasket from heavy Cylinder Head. :~



Silly tight 15mm Sump Drain Plug needed this lot to undo. More :rolleyes:



Using my trusty Britool smaller Torque Wrench, 20nm Plus two passes of 180 Degrees secures Cylinder Head. :~



One unexpected thing. A close neighbour turned up in this. So, a red, white and silver one near where I live and a local driving school uses a higher profile spec one in bright yellow. A frequent sight locally now. :~



Following all those many cold to the bone and soakings right through to the skin I now possess the worst chest infection I ever remember having in all my days!

Paranoid me ? ... No way but, there are times when I suspect the whole Universe conspires to thwart my best laid plans. Once or twice is mere coincidence. However, twenty seven times means the Rain Gods are extracting the Urine! :frown:
 

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Discussion Starter · #35 ·
Small progress update.

Didn't touch any car today, felt too rough with this persistent chest infection. Did make a little progress yesterday.

Firstly, added 4.5 Litres of DIESEL FUEL to the Engine :~



Simply carefully pouring the Diesel Fuel over both Camshafts started the cleansing action immediately. Impressed how clean the Camshafts and their surroundings appeared soon after. :~



Close up of part of the Exhaust Camshaft showing how clean it is bathed in the Diesel Fuel. :~



Then, carefully removed all four Spark Plugs. They had massive Gaps so I reset all four to 0.80mm. :~



I also refitted the Inlet Manifold and only was able to use six of the seven 13mm Nuts to secure it. Access to one of the studs is very difficult and I may have to undo the Power Steering hose fixing nearby to allow my hand sufficient access. That reminds me, I need to do the same to my other ZT-T which only has six of the seven 13mm Nuts in place for the same limited access reason.

Finally, it was my Birthday on Monday. My ever thoughtful older son Martin bought this present for me. Now that is useful. A wing protector. Magnets at each corner hold it in place. Bit stiff straight out of the box but that will wear off with use and so will follow panel contours more closely. :~

 
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