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Z Re-builds Rebuilding your ZX? Post about it here. This is for major rebuild threads only, minor mods and tech questions still go in Z Related Technical

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Old 19-11-2016, 08:58 PM   #1
jamersss
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Shobob

91 Twin Turbo Manual 2+0 I got in Nov 2014. Fantastic upgrade from the previous NA Auto Auspec.
  • Sprayed in Mazda RX7 Red
  • HKS Hi Power Exhaust - Toyz Test pipes 3"-2.5" (resonated) and 3" splits
  • Red Interior
  • Apexi Power Intake
  • Engine has been pulled and rebuilt with receipts ~ 2011
  • Manual convert

Work I have done:
  • Installed wiring specialties loom
  • Gassed A/C (previous compressor was leaking)
  • Converted to NA Power Steering Pump, installed HICAS delete kit
  • Welded up fuel filler
  • Installed nismo side indicators

Goal is to turn it into a reliable weekender, OCD and fix every previous shortcut.

To Do List:
  • Power steering / fix oil leak from multiple unknown places
  • Replace turbo coolant lines
  • Replace alternator wiring loom
  • Install EBC, new injectors, Nistune, Tune
  • Upgrade suspension

As it stands.







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Old 20-11-2016, 12:45 PM   #2
Anti
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Welded up fuel filter?

Isn't that a GReddy exhaust?
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Old 20-11-2016, 01:45 PM   #3
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Quote:
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Welded up fuel filter?

Isn't that a GReddy exhaust?
*FILLER

Me thinks he means the neck from the mouth to the tank.

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Old 22-11-2016, 02:17 PM   #4
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Quote:
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Welded up fuel filter?

Isn't that a GReddy exhaust?
Fuel FILLER. Yes, the neck that is notorious for leaking where the insert goes in place.

That isn't a GReddy exhaust, need a bit more light under the car.
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Old 23-11-2016, 06:58 AM   #5
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Had a fun night last night. Got two of the new turbo water lines in. Absolute PITA lining up the banjo and washers.



Decided to bend the coolant hardline which would usually connect to the under plenum water lines, freeing up room and requiring less hose.




Oil return line looks like it has been through hell




Car as it currently sits, needs a good clean


Z1 delivery came in (new oil cooler lines, oil return lines, Nismo Shift Knob and some other various things).


For reference, old coolant line on drivers side


And passenger side
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Old 23-11-2016, 10:58 AM   #6
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Ha I just did the same thing and replaced all the turbo coolant hard lines. Bitch of a job. The ones I thought were the easiest turned out to be a PITA. I jut put tape around the washers/banjo fittings to hold them in place while I spent the next 30mins trying to line them up. How did that coolant tube get smooshed like that?
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Old 23-11-2016, 11:12 AM   #7
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Quote:
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Ha I just did the same thing and replaced all the turbo coolant hard lines. Bitch of a job. The ones I thought were the easiest turned out to be a PITA. I jut put tape around the washers/banjo fittings to hold them in place while I spent the next 30mins trying to line them up. How did that coolant tube get smooshed like that?
Correct, one's that looked easiest were absolute hell. My method to keep the washers on while bolting up the banjos was by using a dab of gasket glue.

I purchased the car like that, didn't notice until I was working in that area a few months ago. I think something happened to it when the engine was previously out.

Still haven't been able to get off the last coolant line on drivers side turbo. 10mm bolt has rounded

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Old 24-11-2016, 07:54 AM   #8
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Lost my pair of vice grips. Found these bad boys at Bunnings. Absolute amazing.



Compare the pair. Old on left.



New hardline on drivers side in place.

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Old 24-11-2016, 10:24 AM   #9
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What's going on with your turbo? It looks cracked or something?
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Old 24-11-2016, 11:52 AM   #10
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What's going on with your turbo? It looks cracked or something?
Coated in melted plastic. Basically ran cheap and nasty wiring to the reverse sensor on the gearbox, over time the cable tie snapped loose the wiring ended up on top of the turbo.

Lucky it didn't catch fire, and I got a wiring specialties alternator to transmission harness on the way
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Old 06-12-2016, 01:10 AM   #11
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So had a busy week. Got moving on the Z though

- Wiring specialties alternator to transmission harness installed
- New silicone Z1 oil cooler, and turbo oil return lines installed
- Swapped all the fuel lines out (under car, under fuel filter and engine bay to Gates enviro shield). Haven't investigated the task of changing the ones linking to the fuel pump.
- Sold exhaust setup, went back to stock whilst car is being worked on. Will revise a bigger and better setup.

Waiting list, for now:
- Plenum gasket
- Billet Alloy Exhaust Cam Cover Seals
- Timing belt/water pump change (all parts here waiting)
- Tomei 320km/h cluster waiting to be calibrated, then ready to go in.

I am tempted to get the plenum sand blasted and powdercoated.











Old Loom:








Plenum side of throttle bodies, all eww


Leaky seals behind TB covers showing their effect:




Also need to source proper manual GB bolts, previous owner loved their washers -
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Old 06-12-2016, 06:09 PM   #12
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Cluster shouldn't need calibrating... plug it in and away you go.
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Old 07-12-2016, 07:46 AM   #13
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Cluster shouldn't need calibrating... plug it in and away you go.
For some reason when I put the car into ignition, the KM/H bounces up to 60. Leads me to believe it is shorting somewhere.
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Old 11-12-2016, 09:08 PM   #14
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SO I made some progress:
  • Wiring specialities alternator loom in
  • Plenum painted
  • All fuel, vacuum lines under hood replaced
  • Billet Alloy Exhaust Cam Cover Half Moon Seals in
  • All oil cooler lines, and turbo return lines replaced

Now, just waiting on one of the throttle body gaskets to arrive from CarCraze.



I also screwed up majorly, overtorqued one of the bolts on the exhaust cam covers (didn't have the torque wrench set correctly), the bolt didn't snap but a piece of the cylinder head where the bolt is housed snapped off. I am going to liquid weld it just for precaution. Please don't leak

You can see it in the bottom left corner of each image:



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Old 28-12-2016, 08:11 AM   #15
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Everything went to plan. Z now running like a dream, and fixed oil leak(s) by replacing all hoses at bottom of engine.

Flushed the cooling system with about 20 liters of distilled water over Saturday also (fill radiator > run for 20 mins with heater on full > drain radiator > repeat). Got a lot of crap out. On Christmas day had to do a run up the mountains in 30 degree weather, coolant temp didn't exceed 82 degrees. Very Happy.
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Old 24-01-2017, 11:58 AM   #16
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It has been a little bit of time since I posted.

Had the timing belt, water pump and lower plenum replaced by Westside Automotive. Was very happy with the work and care.

Old Belt, all oily.








Look what was found just chilling..


Also decided to get the lower plenum replaced, as the bolt holes were all cross threaded by previous mechanics..





Before cleaning (we both noticed the "left" tag on the left head.


Afrer..








New lower plenum, belt, water pump, cam seals




Final Product


Dean reckons pistons aren't stock. He also said whoever installed the last cam seals were n00bs damaging them, causing them to leak.

Very happy, no more oil leaks.
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Old 16-02-2017, 11:32 AM   #17
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Short lived. I ended up selling the Z over the weekend for a very reasonable price. New owner seems good, so I hope he takes good care of her.

Bought my first Z in 2011 and learnt a lot about the mechanical side of a car. Met a lot of cool people and was so worth it in the end.

Mods feel free to close this up.
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