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 Got my new Car - Ford booo I know haModerators: Jump to page : 1 2 3 4 Now viewing page 2 [25 messages per page] | |
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Miller |
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 ADMIN Posts: 2366    Location: Chesterfield ish kinda sort of | |||
| Roger Red Hat |
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 The TV star Metro GTa 1.1i Posts: 1061  Location: Early, Reading. | |||
| dann2707 |
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 I'm O.K. at stuff Posts: 1405 Location: Leeds - A Better City Than Yours. | THanks alot man  Well, attempted at adjusting my rear drums yesterday as I was sick of having about 20 million clicks to put the handbrake on. Got so far but then it started to get dark so went on with it today. How the car was today. Hopefully you can see the shiny rear quarter and door from having correcting it the other day Started to snow but that wasn't going to stop me haha  Removed the drum by removing the whole assembly inc wheel bearing. Not doing it this way ever again as problems occured. Learn by failure I suppose   Can see the 4 bolt holes where I removed the drum. Adjusted the brakes by moving the cam outwards. Enough so that the drum binds on the pads abit.  This next part was the pain, as you put the drum back on, obviously the bearing system spins hence its job here but that was the annoying part, it kept moving when trying to line it up. Didn't help that it was hard to get the bolts in with my hands, AND everything was ice cold and snowy. Got there eventually after swearing a bit.  Bottom right hole kind of shows the problem how it didn't line up. When I do the other side im removing the 32mm nut instead of doing it that way. This was when I was done, snow!    Also some more correction shots from earlier in the week. Going at it so slowly, but as im doing it im protecting the paintwork afterwards so no real rush to do it all in one go.    Barely any swirls now  Also got rid of the sexy N95 and have my Galaxy S so pictures will be much much better | ||
| Roger Red Hat |
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The TV star Metro GTa 1.1i Posts: 1061 Location: Early, Reading. | |||
| dann2707 |
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I'm O.K. at stuff Posts: 1405 Location: Leeds - A Better City Than Yours. | Got a proper update, hands on stuff the lot So after seeing someones inlet manifold and ports looking like this from an 80k engine I can only imagine that mine, on 123k is going to be worse! Probably why my car has soooo many flat spots in the gears  So onwards and upwards decided to have acrack at it as I am off uni for 3 days yay reading week. It's a big job though, the downpipe and cat has to come off. then the turbo, then the exhaust manifold, then finally the inlet!! first i remove the cover underneath the car, revealing this.  These nuts had to be undone but they were so rusted, had to grind them off    Then had to remove the exhaust by 4 bolts on top, 3 came off easy as anything but 1 wouldn't budge and rounded off!  got leverage? quickly removed the ratchet as i think it might break the pawls inside it!!  So used a thicker extension and used a combinations of spanners to get just the right amount of torque, too much and the socket just slipped off.  BOOM. All off.  Now leaving me with this, turbo has to come off next.  That is as far as I got, did start at 1pm and finished at 4.30pm so a good 3 hours - I would have gotten much much further but I wasted 1.5 hours with the dodgy bolts and that. Hopefully get much further tomorrow !! | ||
| dann2707 |
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I'm O.K. at stuff Posts: 1405 Location: Leeds - A Better City Than Yours. | Pretty much done it! What a bloody job, think i've bitten off more than I can chew on this one. A massive thanks to Dew1911 for helping me out with the Haynes manual, deffo wouldn't have been able to even fathom it without! Got off to a great start by slicing my thumb on the EGR cooler haha, could peel that skin back and see my flesh - rank or what lol  Then begun to remove the turbo which is actually part of the exhaust manifold, all as one jobby. Managed to undo it from underneath by disconnecting the oil feeds to the turbo and undoing 4 bolts and nuts. Then to get the EGR pipe off I had to remove 2 bolts as per the pic but they wouldn't shift at all so had to get some heat on it...   Then removed the EGR pipe, all filled up with exhaust soot as expected   Then after locating a few more bolts from above the exhaust could be removed... Actually it doesn't have to be removed fully from the car, just disconnected completely and pushed back to gain access to botls for the inlet manifold.  Then found the bolts for the inlet and removed it. Quite let down really when I first saw it as it looked pretty clean around the ports.  Stuck my finger in and knew it was gonna be fun haha  Then began to fill it up with degreaser, which did absolutely nothing - rubbish stuff we have here i should have got some decent stuff!!  More finger action, lots of gunk  Started to get a bit cleaner, not too great though  This was the engine whilst I was doing this, see how the exhaust is just pushed back not fully removed.  Intake ports weren't fowled that badly.  Then decided to DIY decat my cat.  All mashed up   After.  Back to the inlet, more gunk being chucked out of it. Seriously hope this will pay off....  Garden was a right state haha oh well.   Mid cleaning the inlet.  After realising the degreaser was doing naff all I went for the mr muscle oven cleaner approach with caustic soda, which foamed up lovely and removed loads but still not enough...       Also rememberd I had some caustic soda from stripping my paint on my bike, and its meant for cleaning drains and all the crap in there so made a super strong solution and poured it in and gave decent results !!    More soot still coming out !!  My EGR blanking valve showing signs of use! brill.  hah this is the solution of crap left over from cleaning it all out.  Then started to put it all back together.  Exhaust back on  That's how far I got before it started getting dark. Absolutely filthy!! dirt won't come off my hands haha  Enjoy. | ||
| Roger Red Hat |
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The TV star Metro GTa 1.1i Posts: 1061 Location: Early, Reading. | |||
| alexwuk |
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| Elite Veteran Posts: 931  Location: west bromwich, birmingham | |||
| dann2707 |
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I'm O.K. at stuff Posts: 1405 Location: Leeds - A Better City Than Yours. | |||
| dann2707 |
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I'm O.K. at stuff Posts: 1405 Location: Leeds - A Better City Than Yours. | Two problems i've come across. But shouldn't be too hard to sort out. • The EGR pipe that attaches to the top of the turbo, the threads inside the turbo are ever so slightly distorted meaning I can't screw the bolts into it. Which is a pain. But my Dads bringing the right tap home so I can re-tap the thread, I just hope it will be easy to get to with the tap as there is limited room. • Where I ground the exhaust off the mid pipe, obviously the thread isn't there anymore so I can't simply refit the cat/downpipe. But pics will tell all in a sec.... Today so far (having a food break might aswell update ha) Safety glasses on can only mean one thing...  Time to get the grinder out You can see the stud that needs to be ground away, above the exhaust hanger.  So then shuffling under the car with the grinder I had a play, basically had to grind away the head of the bolt along with it's weld, so much untill I could see the outline of the bolt that went through the hole. Soon as I saw it I started smacking it with the big mallet. Again all this whilst sqeezed under the car was awful.  Then!  This was the offending nut/thingy  Whilst shuffling under the car i've managed to rub my hand on my freshly corrected door, bet it's scratched but oh well haha  | ||
| R119GTA |
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 Metro Mad Posts: 7653  Location: Tamworth, Staffs | I can relate to that job, as I have stirpped one today for the same problem of the inlet and egr valve blocking up, although I have cheated abit as I have ordered a new inlet for it from Ford as its a company work vehicle and they prefer a new unit rather than the old one cleaned out. I had 3 studs on the cat break off on me which hardly any effort when un-doing but all the other bolts were ok. Looking at your setup I think you could fit the EGR blanking kit if you wanted, have a search on the web | ||
| dann2707 |
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I'm O.K. at stuff Posts: 1405 Location: Leeds - A Better City Than Yours. | I had a mare with the valve that goes to the turbo, both bolts messing up the thread, so had to tap new ones in there! Also i already have the EGR blank on | ||
| dann2707 |
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I'm O.K. at stuff Posts: 1405 Location: Leeds - A Better City Than Yours. | Bit of an update to the problem above, dad brought home the Tap which I needed. However the tap he got was a pointy one when I needed it to be one that looked like this due to clearance in the turbo itself. If the hole went straight through it would have been fine... So I got the grinder out with a cutting disk and sliced the end off creating a tap with a super flat end. I think this is what gave me the next problem though... All going well as per the pic.  The pic doesn't really show how awkward it is to get to as its right at the back of the engine. Managed to get one tapped beautifully, worked a treat I was all happy. Went to do the hole at the back and disaster struck, the tap snapped whilst IN the thread, I could only see a tiny bit of the tap left in the thread. I could have started crying in all honesty !! Thought of the idea of getting a centree punch and try attacking the tap round to unscrew it out - which actually worked I couldn't believe it. So I was kind of stuck what to do with a broken tap. But on closer inspection I checked out the tap and it still had a few threads left on it. So I took a risk and cut off the broken bit on the tap and made this...  Worlds dodgyist and shortest tap haha. And I couldn't believe it actually worked and tapped the thread. So got the EGR pipe all on now, just a few things to do tomorrow morning before it's all good to go !! | ||
| alexwuk |
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| Elite Veteran Posts: 931 Location: west bromwich, birmingham | |||
| dann2707 |
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I'm O.K. at stuff Posts: 1405 Location: Leeds - A Better City Than Yours. | |||
| R119GTA |
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Metro Mad Posts: 7653 Location: Tamworth, Staffs | Snap! not just for the tap breaking but also I broke one of mine when cleaning the threads on the cat, was only a cheap laser set I had to hand at the time, done the job in the end too Got the job all back together bar new the map/boost sensor which I have to wait till next week for. With having a new inlet its good to show you the difference to how it was from build and how it should be  So are you all back together and sorted now? | ||
| dann2707 |
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I'm O.K. at stuff Posts: 1405 Location: Leeds - A Better City Than Yours. | |||
| dann2707 |
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I'm O.K. at stuff Posts: 1405 Location: Leeds - A Better City Than Yours. | Today I got up at 7, which surprisingly I got up proper easy, felt like I had a lie in which was weird !! i'm usually up at like 10 for uni ha And cracked on. The day pretty much consisted of tidying up all the loose ends. Started from the top of the car then went underneath finally. • Fitting the EGR pipe and blanking plate back on, along with securing the pipe back to the engine. • Fitting the boost pipes, air box etc • Getting the midpipe on the exhaust hangers • Fitting the de-cat pipe • Bolting the downpipe to the exhaust manifold. Just a couple of pics building it all back again. Boost pipes on  Airbox back on.  Got it all on and started it up, instantly noticed a difference when i blipped the throttle, it just revved instantly, a bit like a petrol would, proper free revving !! Took it for a spin and it feels so much better, it pulls harder than ever however there is still a bit of lag at first, I presume this is just normal as the turbo has to spool up. Drove to uni and back and it was pouring out a bit of black smoke when the throttle was floored, a good sign as all the crap is getting blasted out! Got home and decided to clean out my MAF just to go 100% with the whole engine clean thing, I attempted to clean it before but didn't get much crud off the larger sensor as per the pic, it had like a green film over it, like what a battery gets when its really old. Also I disconnected the MAF and revved the car and it revved just as normal? I didn't drive it though, any ideas why this is? is my MAF dead you think? Before  After.  | ||
| dann2707 |
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I'm O.K. at stuff Posts: 1405 Location: Leeds - A Better City Than Yours. | Another update from today. A pretty marmite mod to be honest, I quite like it - will look better once the car has been cleaned and lowered for sure. Yellow foglights - did a photoshop before of them and I really liked the contrast of the blue and yellow. I'm not normally the one to buy cheap random crap (was only £4!) like this and stick it on my car but thought why not give it a shot if it looks crap I can simply peel it off and it's not exactly that hard to do. Anyway.. Started removing the original fogs. Which are proper fogged up (lol) inside.  Removed the plastic trim  One out  My car is so filthy, haven't washed it in weeks!   Weapon of choice.  Already made a right mess of it and wasted a bit of film but luckily had like 130cm of it.  I did one layer of it but realised it wasn't as dark as I wanted it.  After the second layer, the poor finish and ripples is from the protective sheet not the actual laminx stuff.  And the fog light done, a few air bubbles but according to the website these will flat out over a couple of days as the air passes through it or some thing like that !! :/  Left one with 2 layers, one on the right with just one layer.  Back on the car     I don't expect many people to like it but oh well | ||
| dann2707 |
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I'm O.K. at stuff Posts: 1405 Location: Leeds - A Better City Than Yours. | |||
| JohnA88 |
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 114 GTa Posts: 1982 Location: Chertsey,Surrey | |||
| dann2707 |
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I'm O.K. at stuff Posts: 1405 Location: Leeds - A Better City Than Yours. | JohnA88 - 19/2/2012 7:01 AM been told it makes the light output yellow at night :/   Edited by dann2707 18/2/2012 11:08 PM | ||
| JohnA88 |
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114 GTa Posts: 1982 Location: Chertsey,Surrey | dann2707 - 19/2/2012 7:06 AM JohnA88 - 19/2/2012 7:01 AM been told it makes the light output yellow at night :/ LOL | ||
| dann2707 |
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I'm O.K. at stuff Posts: 1405 Location: Leeds - A Better City Than Yours. | Another update !! Got some clear side repeaters, a shorter aerial from a Ford KA and carried on with the machine polishing. How the car stood first of all, a few better pics of the yellow foglights etc.     From the side, really letting it down with the orange...     And on..       Car is absolutely filthy - I love it.  Then the shorter aerial. before - the super long fishing rod.   After   I quite liked this shot from my garage.  Then taped up ready for some massively delayed correcting.  Panel done after one stage of Megs #105 on a medium cutting pad.   Then started on the bonnet.   Colli curing   Started getting dark though so this was the last few shots I guess   Happy with todays work !! dan. | ||
| alexwuk |
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| Elite Veteran Posts: 931 Location: west bromwich, birmingham | |||
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