Dedra turbo H630 XGN

[Kevinlincs]

Front struts have been stripped, top mounts/springs etc all cleaned and painted.
New bump stops and dust covers so now all built up ready for fitting.

[Kevinlincs]

The front crossmember had some corrosion around the bumper mount brackets which of course was more than just a bit of surface rust, so needed to be cut out and welded up.
The outriggers also had a few rusty areas but being much thicker steel it hadn't caused any real harm.
So with a few patches of repaired areas and with the engine etc removed I thought I may as well put some fresh paint on the inner wings and strut towers.
Of course this has taken a few trips to get sorted, but thankfully it's now all ready to accept the running gear again, once I get that built back up!

[Kevinlincs]

Once it's hardened off I'll iject some cavity wax into the vulnerable areas like that crossmember, hopefully it'll then last for many a year to come.
Hoping I'll be able to press on a bit more now and have it ready for the AGM...

[Kevinlincs]

A few more jobs done this weekend, tidying up some loose ends that seem to get pushed aside.
Front calipers had previously been stripped and cleaned ready for the new seals and some paint, they're all done now.
The mirror bodies that were painted a few weeks ago are now reunited with the glass and casings.
New screws will be added to the underside once I remember to bring some home from my unit!

[Kevinlincs]

The rear spoiler I repaired a while back still sat awaiting being painted, every time I walked in the shed it reminded me of the task still to do so I set to today.
There was quite a few splits in the back  edge where the spoiler gets used to raise and lower the bootlid, which cracks the paint with flexing.
On consulting my friend who is a pro painter about the best course of action taking it back to the rubber is the only option to get the cracks out.
I then used an adhesion promotor and then the topcoat straight over that with plasticisor in the 2 pack paint so it remains a certain amount of flexibility even after drying off. Primers especially the high build variety are to be avoided due to them becoming too hard and prone to cracking, so I am told.
Trouble is though the rubber is black and the red takes many layers to cover it, near 10 coats in the end as the first 3 or 4 only just covered it up.

[Kevinlincs]

Not ideal paint spraying conditions to hand now that I've given up my small unit that served me well as a paint and repair workshop but at least the sunshine is a great drying agent!
I placed the spoiler on some stilts using the mounting bolts with some stiff plastic lengths so I could do the underside and the new mounts all in one.
A bit of dust and the odd insect but happy enough with the outcome.
Getting it back into the workshop without dropping it or sticking a finger in the soft paint was thankfully successful!

[Kevinlincs]

I've been to see the trimmer tonight to take him the last of the seat material for the retrim, getting the central pattern lined up nicely meant another Metre needed ordering, simple enough but as it's coming from Finalnd it's costly and takes a bit of time although at least this batch came well under the import duty threshold so escaped being impounded at customs.
I've been worried that it has been a silly and expensive part of the rebuild, maybe I should have sourced another set of seats or made do with the blue Alcantara ones I had, but having seen some of the pieces already done I can't wait to see it all done, even if it would have been cheaper to get two cowhides and have it all done in leather!

As for the car itself the engine is pretty much done and ready to connect back to the gearbox for fitting back into the engine bay.
Whilst the engine has been out I've done a few precautionary jobs while access is easy, fitted new steering rack boots, new brake pipes for the fronts and a new line and flexi arrangement for the clutch to replace to 30 year old original, the old and weak power steering rubber lines also got changed while at it. I've also replaced the rubber fuel lines that run along the inlet manifold as these too are old and were leaking, the correct spec fuel pipe that is Ethanol resistant is very expoensive but still way cheaper than an engine fire would be!

[DavidLaver]

With the seats the only person you need to please is yourself, and it sounds like you're going to be delighted with it.

Spoiler another labour of love.

For me interesting "just" to see the structure exposed at the front. 

[Kevinlincs]

Managed to get the assembly lifted up into place without too much drama thankfully, newly powder coated brackets for the oil cooler and intercooler mounts plus nice red engine bay paint meant extra caution in trying not to scratch anything!
A long stud in each chassis rail to help guide the engine mounts up into place helped.

I've started putting things back on being as methodical as possible to try and not have to backtrack any, so far so good...

You're right about the seats David. I did wonder about the originality or not scenario, even thought about just doing them in full alcantara like others, but as you say it's me that's going to be sat in it so why not just go with it. From what I've seen of the pieces Graham has done so far I think they will be a nice and distinctive thing for the car.

[Kevinlincs]

Clutch pipe change now complete, the original was in one long piece with the flexi part of the metal section so as the metal part was quite rusty and I wanted to change the flexi portion anyway I made it all up to suit.
New slave cylinder fitted this afternoon and a short curled joining pipe made up. Should last a few years...

[Kevinlincs]

It's worth mentioning this again, just incase anyone doing a top end rebuild doesn't know, I didn't until the integrale sprang a leak..
When fitting the 2 exhaust manifold studs back into the head they need to have threadlock on them as they protrude through into the cylinder head cavity right where the oil return pockets are..
The other 3 are just in blind holes so are not necessary to threadlock in.
The issue is the hot oil travels down the thread of the top two and causes that horrible oil burning smell.

[Kevinlincs]

With the breather pipes finally all set in position, after having to backtrack to get them in place it was time to finally get out the refurbished turbo.. 

[Kevinlincs]

Starting to look like an engine bay being filled again, soon to be filled more and more!
Some breather pipes and water pipes to renew and a faff trying to remember where everything goes but handy having the spare built up engine as a reference.
Shouldn't be too long now...

[Kevinlincs]

Help needed to identify a rouge connection!
It appears to come from the factory loom and appears original, but I can't figure out (or remember) where it goes to!
It comes from between the power steering reservoir and the ABS unit at the bulkhead, only 6 or 8" long so has a very limited range of where it could go, stretches to the throttle body but no further, so it has a small range of locations to suit.
The plug is a square one with 4 connection pins, wires come into it at right angles.
I can't rule out it going to the relay box that has the black cover over it, but I really can't recall where it goes! The cleanliness of the pins makes me sure it was attached to something...
The wires to it are; a red, a black, an orange and a blue with white tracer.
Any ideas guys?

[Kevinlincs]

I think I've sussed it.....

https://www.ebay.co.uk/itm/192637106116?epid=1534580201&hash=item2cda10f7c4%3Ag%3AGawAAOSwt%7E5bgSv2&LH_ItemCondition=4

This is an ABS relay which looks exactly a fit for that plug, pin orientation and the pin to align the terminals in the correct order, I just need to see if there is a relay on the bulkhead where this plug has been pulled off of, or if I'm missing the relay itself.

Interestingly though I called in at my friends place today to have a look at his Dedra turbo but couldn't even see the lead and plug! Maybe it does stretch under that black relay cover..
The plug is also branded "W.Germany" on the back which would point to it being a Bosch item rather than a Marelli one, another pointer that it is ABS related.

I also had a look around the integrale but couldn't find a thing looking similar so convinced it's not an engine related part, and that car has no ABS which makes sense that it doesn't have that conncetor, different car I know but same engine.