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New Project Chapter - MG ZR T16

24K views 61 replies 15 participants last post by  gnu  
#1 · (Edited)
It has only been 6 or 7 weeks since I closed the last thread when I said goodbye to the Cheap and Cheerful (as in signature).

A new chapter begins today following a quick fling with the VAG crowd in an Audi TT. Not really sure on a direction yet in terms of styling or tuning. I have to say this is a rebuilt T-16 engine with a GT28RS which is currently plenty fast as it is. SIck thing is my insurance was ÂŁ100 only more than my last Rover :s (Good old Adrian Flux).

First thing to go will be the alloys followed swiftly by a suspension swap as I believe in has a Koni front and Gmax rear - Coilies?? Possibly.

Let me introduce my new project -

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The car shell has covered 60,000 miles and the Engine has now covered around 82,000

Engine with:

*New bearings/ gaskets throughout
*Tickford turbo pistons and rods
*Gt28rs Turbo running approx 14psi
*Snake head downpipe
*Over boost chip
*Air Filter
*Baileys dump valve
*Battery relocated to Boot
*Fast Road uprated Clutch

Chasis
*Zr 160 Struts with Xpower Diesel lowered Springs
*Zr 160 front brakes with black diamond groved disks and ebc red stuff pads
*Zr 160 rear disk brakes with black diamond groved disks and ebc oem pads
*Goodridge Braided Brake Hoses all round
*Magnex Oval back box and de-cat

Misc.
*Full leather interior
*BRM Gear Knob
*Leather Armrest
*Dash Pocket
*Boost Gauge
*HIDs
 
#5 ·
X power springs ordered for immediate fix. I couldn't get it on my drive! Had to use planks of wood, PMSL

Managed to take it out for a spin before doing so - I did actually buy the car without viewing or driving - against all my normal instincts but...........Damn it was worth it! Really didn't know what to expect with the GT28 turbo on - what a BEAST!

I have a few things to do over the next few days as I have taken some much needed holiday - great timing!
 
#9 ·
I've had a productive day off even with the after effects of badly twisted ankle yesterday.

First thing, whilst waiting for my springs to arrive I changed the rear lights back to the standard.

Just as I finished they arrived so it was off to the garage.....

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On the ramps gave me a chance to get a closer inspection of the car. I'm still finding things out and updating the spec on the first post of this thread!

Anyway, the rears were indeed red lowered springs and in reasonable condition. The front however were not so good. I was informed that they were Koni. The mechanic and I agreed that the strut was OEM and the spring also! The spring was so under pressure the coils were closed and rubbing causing corrosion. They were in pretty poor shape. Sorted now though. Xpower diesel or Eibach depending on your view on just like my last diesel. Instead of not being able to put a finger in I can get three. Not everyones cup of tea but it is lower than standard and practical for me.

To the other findings and I've spotted an oil leak....the joint in line with the filter. Need to do some research.

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The drive home was very good. It felt flat through the corners and as comfortable as my last. Very happy.
 
#12 ·
If its genuinely running Tickford/M Series rods and pistons then get that boost up to 15/16psi. Fun arnt they? :p
So the previous owner on Rovertech says. All I can recall was the builder of the Turbo wich was AET? I was told it could run to 20psi?? but as a daily driver for his partner it was set to 12. He did say to get the most out I would need a decent electronic boost controller but I have to say its an animal at the moment!

You haven't got any clue about the oil feed/return pipe have you? or any wheels around?
 
#15 ·
Today has been FANTASTIC!

To add to todays suspension work there has been enough light in the day to remove the towbar (yes, I know WTF!) and paint the yellow callipers in Hammered Black (Hammerite paint) and...............

have a set of MK2 11 spokes:chewie: Never thought I'd actually find a set.
The only dilemma before fitting is what colour to paint them??

(pics of course to follow)
 
#16 ·
A week on and I have managed:

-Adjusted the timing, fast idle and throttle cable.
-Cleaned the throttle body
-Fitted a Manual Boost Control - now running 17psi
-Raised the clutch bitting point an inch whcih has transformed it.
-Received but not fitted front Red stuff EBC pads.
-Received but not fitted Temperature Control Sensor
-Received but not fitted Citroen Xsara mist jet washers
-and finally got back today mu refurbed wheels....


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#19 ·
Mobile camera doesn't do them justice. I'm very pleased with them and had thumbs up from various drivers and friends. The 45 profile instead of 40 has helped with the comfort. Pure luck miti kid tires but I will keep them that size.

As for the MBC, its temp until I can afford an electronic one. The extra 6 psi has made a huge difference. Tourq steer is silly if you drive it hard which is not something I do.
 
#22 ·
What a naff day!

The morning started well. A new Coolant Temp Sensor fitted in minutes and instant idle and throttle fix.

I then set about, with much assistance from my Dad today to change the track rod ends and fit some new pads. 5hrs later and one track rod end fitted and no pads! Why?

The track rod end was a pig! It had fused to the locking nut and had to resort to the grinder! The top nut came off with ease.

With the rod end fitted we set about removing the caliper. Again, not the origional plan we started with as it was just going to be the pads but I had wronly taken the advice of the previous owner - lesson learnt. The calipers are not ZR 160 but 600Ti. A bonus on one hand but a bum on the other as the pads don't fit.

The issue arose when tryng to remove the carrier pins. BOTH had seized. One came out with a big hammer and punch and we thought that was bad. The bottom - OMFG! We tried everything. Took the carrier off and set about with every conceivable tool in the garage (breaking a few of them) tring to get the pin out. It looks like the rubber had found its way inside with the pin, melted and.......well I'm gob smacked - nothing like it! Got there in the end though through pure persistance.

Anyway. I need another new set of pads, a caliper service kit and to fit the other track rod end. It is all back together and working.

What a day!
 
#23 ·
What a contrast to last weekend!

Despite having to start the day at 7am erecting marquees for the local village fete the sun was out and we were ready to start ensuring we had plenty of light and hours left in the day if we hit the same problems.

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Today we set about attempting to replace the remaining track rod end, calliper slider pins, red stuff pads and changing the discs over to the correct side.

We couldn’t believe it. Both sides stripped down and the track rod end done in 30 minutes. All too good we thought but our luck continued. We cleaned out the existing copper grease from the slider pin holes after the popped out with ease. New rubbers, pins and silicone grease had them moving as new.

The discs were taken off and rubbed down taking all the existing rust and put back together on the correct side in only an hour. Brakes were then bled – so much air in them! I now have a very solid pedal. Pads need bedding in so I’ll update you on the quality of the pads at a later date.

With all this done in good time I spent some time repainting the yellow callipers a lovely pearlescent black which sparkled in the sun. The contrast against the new pads is obvious.

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#26 ·
Nice work! The black brakes look much better than the yellow. :broon:
grand job mate looks well nice
Thanks guys.

The yellow was a bit extreme even for my taste and despite them being large 600TI calipers they still look lost behind 17s.

My concern is that the rears are just as bad i.e. full of air and in need of a good refurb. So I plan to strip them and replace the greenstuff pads for OEM or equievelent and again switch the discs over to the correct side.

The good news is that the track rod ends has made a noticable difference to the feel of the car.
 
#27 ·
Another update.

I had a day off yesterday and with some assistance managed
*Re locate the boost gauge from the drivers air vent to a pillar pod
*fit led side lights to match HID system
*change the crank pulley
*fix the leaking oil cooler pipe leak by removing and adding new o rings and spacer
*remove and refit the front engine mount - I had received the qouted part which niavely I took on face value and it was the wrong part.

I still have the rear calipers to refurb and replace the pads which I have.

Not sure wants next lol
 
#28 ·
Quick update. Another productive non productive day. I'v had the front off again to change the discs back the way they were. My apologies to all, I was given duff advice and should have checked first. I did however notice that the caliper bolts with the spacers on to fit the Ti are very warn and need replacing. I believe the bolt is only getting 2 or 3 threads in because of the spacer?

Having done the front I moved to the rear. Oh dear. No handbrake and leaking seals in both. About to purchase a set of refurbed as I'm not even going to start to pull them apart. For the time being I've put back both as was and bled both as best I can until I get the replacements in a few days.
 
#29 ·
The car is off the road at the moment as its no longer safe IMO. I have to say there has been something in the bake department but IMO I've had one out of 4 calipers working but with air throughout the system due leaking rears not to its capability.

The refurberd zr160 260mm rear kit will be here tomorrow and should also sort out the handbrake (as the operation works just not the calipers).

Also, I've ordered some longer front caliper mounting bolts to secure the TIs with spacer as these are clearly 5mm short. The current bolt is a M10x26mm (1.0mm pitch). Once all fitted I shall change all the brake fluid.
 
#30 ·
Quick update.

DV removed. Running without and awesome chatter.
Front wind deflectors fitted.
Chequer Plate styled bespoke Black Rubber Car mats fitted.
Fixed Rear Wiper wash feed.
New Kenwood CD/USB installed.

A report on the brakes - all working well. More feel on the pedal. Disks are all glazzed nicely.

For those who have not seen I popped my virgin Rovertech forum meet bubble with eventful results. No Rover meet is complete with out the AA van. Unfortunately, it was for me. I lost all power. Nothing, no dash lights and no immobiliser. The culprut was the main power cable from the starter motor to the fuse box. If it wasn't so funny I'd be shocked. The cable was literally found in two pieces underneath some electrical tape and plastic covering. The AA man couldn't understand no voltage getting through the cable until he uncovered this. I can't repeat what he said on a public forum. Anyway, he soldered a new end to make a one-piece cable and reconnect to the fuse box. I'm spending today reviewing and replacing all the cable connections.