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

[johniban 59 1 Cars]

just read through all this! looks awesome

[welshpug 1,622]

well, to me it looks a bit ropey tbh

 

Got some Team Dynamics pro race 1.2's coming, so a bit more weight but an extra inch of width and more air to the brakes, not that I've ever found them lacking, I do need to improve the rear damping, some turrets or a pushrod linkage system would be ace!

[johniban 59 1 Cars]

Your'e doing a superb job on it! used to have the odd one or two come in when i was at Citroen only diesels though.

[welshpug 1,622]

Done nothing to this since mapping but drive it and put fuel in, after replacing that fuel pump.

 

20150311_091508 by WELSHPUG, on Flickr

20150311_090633 by WELSHPUG, on Flickr

 

 

This clips into a small anti-surge cradle affair in the bottom of the tank, works very well, as long as you remember which way round it goes and to fit the pickup pipe/gauze filter!

 

 

The Walbro replacement units are a lot smaller than the Bosch original unit, so had to pack out the plastic/rubber bits a bit.

20150314_161512 by WELSHPUG, on Flickr

The supplied pickup filter wasn't any use as it was for an upright application, but the inlet is smaller than the Bosch pump so the original pickup tube didn't fit, luckily the handy bits of packaging they come with did the trick...

 

20150313_115621 by WELSHPUG, on Flickr

 

20150316_194905_LLS by WELSHPUG, on Flickr

 

20150316_194931_LLS by WELSHPUG, on Flickr

 

20150316_194736_LLS by WELSHPUG, on Flickr

 

 

It has been a little reluctant to start first turn but fires fine after a bit of pedal prodding and cranking, once running its no problem, I;d also noticed that part throttle cruise, i.e 5th at 70 was sometimes not as smooth as it could be, a glance at the lambda and you could see it was trying to correct it quite a bit, I recalled Sandy was not a fan of the PTFE gaskets, though I had never had any issues on the standard inlet, I did have a pair of Elring gaskets so decided to try them

20150411_101608 by WELSHPUG, on Flickr

 

That's after a little clean up, I couldn't remember leaving it particularly grubby but it was, so might have been part of it maybe?

 

Also swapped the starter motor at DCC's suggestion, not sure the starter made much difference, as I still had to prod the throttle pedal a little to get it to catch, no popping this time though, but once it did it settled to a rather low idle.

 

20150411_103658 by WELSHPUG, on Flickr

and the warm idle was quite steady too.

 

20150411_105122 by WELSHPUG, on Flickr


Still seems a little rich to me on part throttle, can only think it would be due to the new fuel pump though at no point during mapping was the old one struggling to keep up with demand, I think I will get a spare set of injectors serviced, another set of picos for the front set and go and see Sandy again.

[rallyeash 155]

Sandy made me take my PTFE gasket off prior to mapping!

[dobboy 231 2 Cars]

WP, i found a 1.9D one of these in a scrappies last week. If there's any bits i can get for you let me know as i'll be going by it next week, it had good lights etc on it, and car was near complete.

[welshpug 1,622]

hmm, if the keys are there and it has a CL fob I'd love the fob and the receiver from the roof console!

Any other bits I'd be after are unfortunately specific to the 16v


I did more this afternoon.










I just need to figure this dimension then whack a gert big ole in the bulkhead!!

[dobboy 231 2 Cars]

I'll have a look and see if they're there.

[welshpug 1,622]

a brief update, not yet got the Satchshift fitted, I haven't got any drills small enough to get anywhere near the bulkhead to make the hole, also not having access to anywhere flat or a ramp makes things very difficult.

 

Got hold of some 205 Tarmac rear dampers, so much more chunky than the konis and the balance front to rear from a brief test drive is much improved.

 

20150523_163714 by WELSHPUG, on Flickr

 

 

 

As the ZX seems to sit quite low and these dampers simply will not compress by hand or lever, I had to get creative in their fitting!

 

20150523_171537 by WELSHPUG, on Flickr

 

 

I had also been experiencing some light vibration from the nearside rear brake under heavier braking, the discs had got particularly rusty when parked up last and seem to have glazed over and picked up some pad material in spots possibly, so Ebay to the rescue with some genuine rear discs, made sure the flanges were spotless before fitting of course.

 

20150523_160657 by WELSHPUG, on Flickr

 

20150523_160650 by WELSHPUG, on Flickr

 

 

 

20150523_161513 by WELSHPUG, on Flickr

 

20150523_173527 by WELSHPUG, on Flickr

 

 

and lastly something to have a fiddle with tomorrow possibly, a cobbled together used bits, thermostatic takeoff, pipes and an oil cooler, pipes should hopefully be long enough this time, the old Swaged set I still have weren't quite and these are a good few inches longer.

 

20150524_203740_LLS by WELSHPUG, on Flickr

[johniban 59 1 Cars]

Nice idea on the shock fitting! never thought about that

[welshpug 1,622]

https://flic.kr/p/v8h1RN

 

fancied a change of wheels..

Edited July 16, 2015 by welshpug

[welshpug 1,622]

Speedline sl434 by WELSHPUG, on Flickr

[Tom Fenton 1,525]

Sorry but that would do my head in, would the money spent on the wheels not be better spent on having the wing door tailgate coloured in to match the rest?

[welshpug 1,622]

no, I want the rest to match the tailgate and wings, that's far more than I spent on these wheels thankfully, I picked them up for much less than most I have seen advertised for, probably about a grand of work in paint at least there.

Edited July 16, 2015 by welshpug

[S@m 156]

Nah go back to the C5 Steelies.......and sell me the 434's.

 

Just kidding, it looks real good but, in my humble opinion, not as good as it would on a set of Citroen Indianapolis 15's, which i think was the original wheel for the ZX 16v, despite everyone thinking they were Saxo VTS only.

 

EDIT - i was wrong, the indianapolis was only offered as an accessory and then on Ph1 Xsara. Should check the system before i open my mouth!

Edited July 16, 2015 by S@m

[welshpug 1,622]

yeah, I did have some on it for a while Sam, they were used on the Dakar i think, or the other ones with more lines on the face.

Edited July 16, 2015 by welshpug

[johniban 59 1 Cars]

Not a fan of them wheels personally, would look good on a set of zx 16v wheels if you could find some

[welshpug 1,622]

I have some, they don't fit over anything bigger than 266mm, which is why the later euro spec cars had the same wheels as the early xsara vts, which arent so nice looking and are narrower than these wheels.

[S@m 156]

I agree, the early Xsara VTS/ZX 16V wheels aren't very nice at all but i did once straight swap a set for a set of C5 Steelies, and the guy thought he was the one getting the steal!

 

Are you running 283mm GTI6 brakes then? If so, it more or less is a Dakar!

[welshpug 1,622]

yes, have been for years!

[Plumbob 66 1 Cars]

Quick question about your throttle body setup, I see you're using the standard fuel pressure regulator as you've got a modified standard inlet and standard fuel rail, but where are you getting the air supply for it now the large collector has been chopped off? Have you just connected it to the back of your new air box?

[dcc 855]

Air supply for what?

[Plumbob 66 1 Cars]

The fuel pressure regulator

[dcc 855]

Dont need one. Its mapped to a set pressure, why would you want to vary it?

[Plumbob 66 1 Cars]

I have no idea mate. I saw the other day on another thread that somebody had used an adjustable one, either you or WP or Allen popped up and said an adjustable one wasn't required and a standard one could be used just fine, I know the standard one uses air from the inlet and I've seen that WP's setup has the standard regulator in the fuel rail... Was just wondering how it was hooked up.