Re-doing the rats nest

Jit · July 08, 2006, 05:37:38 PM

Right, have just got in from removing all the gubbins surrounding the rats nest and it looks ready to start replacing pipes!

However, just a few questions:

If a pipe leads into a check valve (the little green thing), does the pipe coming out of that check valve always have to connect to something?

Can all the pipes be changed with the car on the ground...my driveway is on an incline and i dropped my fc onto the floor when jacking up on it last time! By this i mean, the pipes coming from the turbo pack..can i access them if i remove all the intake stuff?

Finally what size spanner do you need to remove the knock sensor?

Thanks in advance:Thumbs-up

shaunwil · July 08, 2006, 08:07:49 PM

Theres a good write up here :

http://www.robrobinette.com/hoses.htm

Shaun

Jit · July 08, 2006, 10:33:29 PM

RIght well i started tackling the job today by taking the whole engine bay apart!

First thing to come off was the Intake arm complete with upper IC pipe. Next was the lower IC pipe. Then i removed the pipe which comes off the turbo y-pipe and joins the y-pipe to the lower IC pipe. Next off was the UIM and TB assembly with the pressure tank. Then i removed the stock airbox assembly. Next step was to remove the airpump. Then removed the Primary turbo inlet pipe.

This is what the engine bay currently looks like (might take some time to work as i only just submitted it and it needs to approved by fotopic)

http://jitesh512.fotopic.net/c1016073.html

Tommorow ill be removing the rest of the secondary turbo inlet, possibly the y-pipe and the solenoid rack as well as the knock sensor so i can fit another one.

Im off to pirtek on monday to get some new hoses and then off to halfrauds for some cable ties.

Couple of things I noticed while removing the parts which caused me a bit of concern...

The last person who would have worked on this car (a vendor from the list at the top of the page) was obviously some soort of cheapskate...i cant for the life of me see why as for the level of work they are doing, theyre charging a bloody premium! I would expect better quality workmanship from kwik-fit.

Firstly, the turbo inlet pipe wasnt actually bolted onto the turbos...merely held on by the studs......seems a bit odd.....are nuts really that expensive??

The airpump tensioner bolt wasnt the right one at all....it was sort of squashed into the groove on the tensioner arm! They could have atleast used a washer to spread the load!! This is really bad workmanship and its why ill tell everyone i meet to steer well clear....

interloper393 · July 09, 2006, 03:38:13 PM

nice work bud! keep us posted as im going to upgrade to better hoses with metal clips to stop um poping off lol.. mite as well if im rebuilding it anyways .. all i need now is a car to rebuild lol

Fish · July 09, 2006, 06:39:30 PM

Dont forget the cut the old pipes off the solenoids. God forbid you break a pipe, let me know I have my old set knocking about.

Fish

Jit · July 13, 2006, 11:06:00 PM

Right just a little update...havent really managed to get much done as ive been busy planning my girlfriends birthday surprise////

got a little bit done today:

First thing today was to detach the ignitors or coils or whatever you call them... 4 10mm bolts and one 8mm for an earth strap. THen removed all 3 connectors from the coil end and all 4 plug leads (making a note of what goes where!)

Next step was to start removing the solenoid rack. Held on by 5 bolts (two 12mms hold it to the housing, one 12mm holds an earth strap on and 2 10mms. Dunno if these were sposed to be on quite as tight as they were but hey ho..
It was at this point i realised that there are some fuel lines atached to the bracket which holds the solenoids so these needed to be removed. At the same time i decided it would be easier if the black cannister was out of the way so i removed this as well.

Then removed 3 fuel lines from the assembly. Also removed the coolant line ( i think its coolant) from the filler neck to the rats nest assembly. At this point the rats nest assembly feels like it wants to comeup..but there is still one fuel line right at the back which is holding it on...thats tommorows job!

For the time being, the engine bay looks like this:

http://jitesh512.fotopic.net/p31396196.html

Another view: http://jitesh512.fotopic.net/p31603961.html

Lifting up the bracket...the solenoid rack is almost off....if you follow the 3 fuel lines from the bottom right of this pic, you can see theres 2 hoses sill attached. Once these are off, the whole solenoid rack should come loose (but not off) (once you detach all the vac lines of course!):

http://jitesh512.fotopic.net/p31603962.html

Then its time to start swapping!

allstaruk · July 14, 2006, 01:20:03 PM

You don\'t need to remove the fuel rail hard pipes if your only trying to get the solenoid rack out, if you undo all the philips head screws there are some that are a right pain at the back between the rack and the bulk head then the solenoid rack will lift free fromt the fuel hard pipes.

Jit · July 14, 2006, 01:53:20 PM

lol, i know but it looks easier to do it that way as all the philips screws have rounded heads...this way i can remove the screws using somple pliers and put some nice new ones in....

Im having to replace a couple of fuel lines as i couldnt get them off so i used wire cutters...otherwise i swear my back was gonna sieze!

Mini update...just removed the alternator and air control valve....and that 2 fuel lines. So once the vac lines are disconneted, the whole assembly should come off! And i can start replacing!

Just finished making a massive vac line diagram that i can colour code myself and mark off as each hose is replace...that way i can tell if something has gone wrong!

allstaruk · July 14, 2006, 02:08:03 PM

You mean like this one, give me you e-mail address and I\'ll send you the original file,

Alan

Jit · July 14, 2006, 02:08:49 PM

errr....what one lol!?

allstaruk · July 14, 2006, 02:10:23 PM

Would help if I added the pic

Jit · July 14, 2006, 02:46:59 PM

Hmmm that actually looks pretty useful! my email address is j.mistry@herts.ac.uk

i just finished making this one.....just gotta find somewhere to stick it lol!

http://jitesh512.fotopic.net/p31622301.html

allstaruk · July 14, 2006, 03:19:13 PM

:rollin Not really needed thought i printed the colour one at A4 and it was more than adequate.

ds2000 · July 14, 2006, 03:22:59 PM

Looks like we\'re both doing the same this weekend

Jit · July 14, 2006, 03:26:12 PM

lol, i know its not really needed but my eyesight aint great hence the size!

Just got the nest off now! So time to start replacing.....oh wait, i havent bought any vacuum hose yet lol!

Does anywhere know any cheap supplier of braided fuel line...while im here, i may as well replace these as the shrouding for some of them aint looking great!