99 replies to this topic

[DarrylB]

Hello all, thought I'd put one of this project things up due to starting a bit of an over haul on my VX.

Where to begin? Right. Some time in May this year my oil cooler went pop, I sourced a second hand one from Liz, got my self all mucky and fixed it and got my self motoring again...

...until the day after the final round of the BTCC, 17th October. I went to work and when I went down to the car park to go home I was greeted by this now-familiar-to-me sight:

Oil pee


Expansion tank filled with chocolate





I was dis-pleased to say the least.

I decided right there and then that there must be an underlying issue and I needed to take the car off the road to do some investigation.

As luck would have it a mate a work was selling his old Ford Ka.......now I know what your thinking ITS A KA but hear me out!

It's an X-reg, 1.3 Lux in dark blue, 49,000miles, cream leather, AC, heated front and rear screens, remote CL and boot pop, alloys, Tax until MAY 2012, MOT until Dec 22nd. It has a patch of rust on the A pillar and few dents but other than it was in perfect working order. So I bought it! How much did I pay for this little gem I hear you say.....TWO HUNDRED AND FIFTY POUNDS!

Yup.....bargain tastic! So now I was motoring again and could tend to the poorly VX in a timely fashion



Updates to follow......

[DarrylB]

Can mod change the title to say 'Mini' instead of 'Mine'? Ta!

Pics of the Ka:

[techieboy]

Can mod change the title to say 'Mini' instead of 'Mine'? Ta!

T'is done.

[DarrylB]

So I got on with the business of gathering bits.

I immediately placed an order with JG (http://www.mangomotorsport.co.uk/) for all the complete set of bolts to replace just about every nut and bolt on the car

Next I got on with ordering a decent dremel and a pop up gazebo as there is no way I could fit the car in the garage as it full of junk important stuff.

My second stroke of luck after the Ka find then came along: GTVX220 put his for sale thread up which contained an oil cooler and much needed drivers door hinge, as my door sags about half an inch when you open it.
So I snapped them up.

I then got on with getting the car prepared:




Whilst waiting for parts to arrive I thought I'd get on with fixing other bits, the heater for example. So I whipped it out. So glad my battery has a handle!!!!

[DarrylB]

Can mod change the title to say 'Mini' instead of 'Mine'? Ta!

T'is done.

[DarrylB]

Battery and heater out:





I've cleaned all the bits up and I'm currently soaking the rusty bits in Bilt Hambers Deox-C. Once they are rust free I will spray them and reseal the heater.

[vocky]

I would guess that your oil pressure relief valve is stuck shut on your oil pump, thus causing two oil cooler failures, best add that to the list of things to fix

[DarrylB]

Before:


During:


After the first 'bath':

[DarrylB]

I would guess that your oil pressure relief valve is stuck shut on your oil pump, thus causing two oil cooler failures, best add that to the list of things to fix

Ok, is this an easy part to check/replace?

[vocky]

oil pressure relief valve is mounted on the outside of the oil pump, I think it has an 8mm or 10mm hex allen key plug on the oil pump casing, it's located below the water pump near the crank pulley. remove the plug and then try and get the relief valve out, it may be seized, otherwise get a replacement oil pump

[DarrylB]

This weekend it was time for the 'big one' the clam was coming off!

I had my penetrating oil and dremel at the ready, the playlist on my iPhone set and the instructions printed that were kindly sent to me by Winstar. I was prepared for day of hell.

I started at 10.20am on Saturday and by 1pm when I got the 'dinners 5 mins away' shout, the last bolt came out

I had a few surprises on the way mind....... photos will show you what I mean:

Seats out, speakers out, plastic back off.....what the hell! no wonder I had a few rattles...look how many nuts and washers I found


ALL of these were loose on the rear shelf:


A bit worrying as I'm not sure if they should be on the car! nothing seems to missing apart from a few washers I think

Next I got with removing the roll bar cover and I found a PEN under it...and it still worked!

[ChrisS1]

Hmm 'interesting' door cards!

[DarrylB]

After a fantastic ham hock casserole, I enlisted the old mans help and off came the clam. I'm hoping the front clam will be just as easy!





Broken exhaust mount:

[DarrylB]

Hmm 'interesting' door cards!

They're going! Don't worry

I've got some paint from paints4u and will be matching them to the body colour as that's what they are underneath, but it was soo badly painted that it started to crack and peel.

That was a £3 quick fix during a top dear episode!

[DarrylB]

I was zipping along now!

The exhaust came off with no trouble and then I saw the reason for my cold start ticking, one broken stud:

See my other thread about my little hiccup with drill bits on getting this stud out

All the other studs came out with no trouble. I have new studs, nuts and a new gasket (I just have to find them!) ready to go
The manifold is crack free thankfully which was pleasing.

Started draining sludge and fluids and removing the offending oil cooler:


Lovely mess to clear up:




With Saturday out the way I'd got a lot of stuff removed. I was a happy and but tired chappy. Nipped over to a mates for some fireworks and bonfire, had obligatory toasted marshmallows

[Ormes]

ALL of these were loose on the rear shelf:

Hand built in England

Good read

[DarrylB]

oil pressure relief valve is mounted on the outside of the oil pump, I think it has an 8mm or 10mm hex allen key plug on the oil pump casing, it's located below the water pump near the crank pulley.

remove the plug and then try and get the relief valve out, it may be seized, otherwise get a replacement oil pump

Fantastic! Is there anything you don't know when it comes to the VX220?


On a side note: As I've been removing bits and bobs, I've been labelling and bagging all the nuts and bolts until I get a nice parcel from JG

[DarrylB]

Today I got on with doing the jobs that are made 100x easier with the clam off.

I was able to put my rear poly engine mount bush in; with the clam and exhaust on I bent an extension bar and still didn't get the mount off....It took less than half and hour with all the other bits out the way.


Then I fitted my M-tech short shifter, again, with the clam on the is a huge PITA to do!
Following Mark Verbooms guide, I had the pin out in 6 hits with a punch and a club hammer.



Then covered up all the important bits and got the APC and Degreaser out and gave everything a basic clean...pics tomorrow

So that's where I'm at now.

Edited by DarrylB, 06 November 2011 - 06:17 PM.

[JG]

Bolts on their way to you shortly, just in time to put it all back together. Nice thread btw

[DarrylB]

Fantastic, looking forward to getting them!

Here's my list of jobs left to do now that I have a daily drive and the car in bits

Repaint the door cards and dash plates
Repaint the rear spoiler due to flaky lacquer
Get the passenger door bubbles filled and door painted
Replace drooping drivers door hinge
Re-seal heater matrix and refit
Replace the aerial base as the rubber has perished
Paint callipers and hubs
Repair worn seat bolster
Fix rocking seat runner and repaint them
Fit new thermostat
Overhaul the exhaust with all new gaskets and nuts and bolts
Drill out broken stud

That's all I can think of for now

Cheers to everyone that has helped so far! I'm sure I'll have more questions as time goes on

Love this place!

Edited by DarrylB, 06 November 2011 - 06:43 PM.