96 850R wagon slow build thread

rado · 2018-04-02T09:11:35+00:00

Oh the original color is dark gray pearl with 172 k on the clock automatic

Jamest5r_

You doing the O ring on the pick up pipe in the sump? If so double up, it's the only way 😁 lots of info on UK Forum's etc one O ring just doesn't cut it

rado

Jamest5r_
How you doing mate ? Been a while

Jamest5r_

rado Flat out with my business mate, wasn't planning it this way but sort of fell into a niche of custom building golf carts and creating people's dreams for a lot less than the big companies do because I don't have the overheads but have ocd so everything leaves perfect lol custom paint (never do two the same golden rule) all individual, whatever spec they want, lithium, lead acid battery etc it's pretty cool but also stressful
Can find the business page on Facebook "St Andrews Golf Carts"
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rado

Jamest5r_
F'kin awesome mate , nice work 👍

242GT

For those with an 850R wagon and need parts , this is on ebay in the UK ,
https://ebay.us/m/fILcef

rado

242GT
Yeah noticed that one when it popped up 👍

morch_66479

242GT a few people commented on the seller's lack of replies for this 850R, see discussion: https://www.facebook.com/groups/116777906470/

rado

I got hold of an extra turbo air box from Mark so I can keep my original safely in a box and made this work over the weekend...

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It's the first start of going back to standard air box and so I can fit the va5t catch can . Anyway needs finishing off but will work .

Also got to fit new boogie cords

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Slow n steady lol , inlet manifold off again over the weekend if no rain 😉

morch_66479

rado how's the inlet manifold dismantling?
I need to do mine to replace the long pcv hose that wraps around the front and side of block.

rado

morch_66479
Not started yet mate , it'll be i think the 4th time it's been off lol

Jamest5r_

morch_66479 Do not remove the bottom bolts, just loosen them, manifold is slotted and it'll pull up off them, if you take them out you'll have heaps of fun lol, the dipstick bolts are fun as well, various ways but it's mostly blind, I found leaving it attached to the block worked best for me

morch_66479

rado let me know if you have any tips for this task as I'll be doing mine at a later date

rado

morch_66479
Savlon mate for scaped knuckles , it's tight down there lol . Na , tbh I always find the 12mm bolt that holds the dipstick to the manifold a bugger to get back on as you literally can't see what you're doing . Rest is pretty easy .
Oh , make sure you tighten the manifold back up , I once went for lunch came back out thinking all was tight started the car up and some tiny flames came out , scary stuff 😀

rado

So it seems I'm really taking my time over this lol people keep turning up with beer half way through what I'm doing Arrgh 😀

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That's the last time it's looking like that

Over the weekend I've managed to change most vacuum lines from blue to black , ran out so bought more today .
Inlet manifold off , plumbed in va5t hoses for catch can , evicted ipd air box , catch can and all hoses related to catch can and new top hose for pcv

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Now i do like polished alloy ...

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I was near ready to give the fuel rail and manifold another going over but had a visitor um...yeah , beer !

The manifold was a breeze this time around , even the dipstick bolt seemed easy .
What i wasn't overly impressed with was the 10mm bolts holding the manifold on were not really tight ( last time it came off would have been when the head gasket was done ) by a volvo guy .
Anyway not too much to do , might do the power steering hose while everything is off lol

rado

Just a brief update as managed between the rain to get a few hours done .
Cleaned the pcv box, fitted the top hose , polished the Inlet manifold 600 1200 1500 then 2000 wet n dry . Fitted the manifold but this time I've left out that spacer

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And what a difference leaving that spacer out as I can leave the bottom 4 bolts in and rest the manifold on to get the other 3 bolts in and can actually see the dipstick bolt to do that up . That spacer was a pain as it's not notched out like the manifold !
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Almost back together

242GT

Nice work mate , you've been busy as by the look of that , lots of manual work.
Interesting the those inlet studs arnt long enough to allow the spacer

rado

242GT
They're long enough as I've had that spacer on since I've owned the car mate . Just not notched out like the manifold . Every time I've taken the manifold off in the past I've got to hold it and get a couple of bolts started as now just hang it on the bottom bolts . Damn sight easier.

rado

Almost back together , only had a couple hours on it today as the weather has been shite all weekend !

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Now the vast instructions say rhd may have to bend the ac pipes , I found it didn't BUT it says nothing about the rip pipe being in the way , so I've had to give it a little love tap 😀

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Seems to have done the trick 🤔

Just a few bolts to de-anno and polish up

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And finish off the maf into the box .

I've been holding off some time as i ordered some do88 hoses in July and still waiting on the 2 water coolant radiator hoses , promised earlier September 😑

rado

Just thought I'd carry on for an hour , fuel line bracket is finally on yey . Strut brace came out looking good i think ..

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I've still got the nice new coolant bottle etc to put on but as said previously , waiting on those 2 hoses ...

rado

Sorted the modification on the airbox and put the old k&n panel filter in and started it up , no problems cool . Good to hear it again but the ticking is getting louder from the pick up pipe .
I've got the gasket kit and I did start the process of dropping the sump a few weeks ago but stopped for some reason as I've read that you have to jack up the engine to undo the engine mount drivers side .... Here’s why I stopped as I wasn't keen on a bit of soft wood on the sump to use to jack up although I'm sure I've done this in the past @Jamest5r_ tell me it's only nuts and bolts again mate lol
Seems a long process watching the video getting the sump out , is it ?
I got to change the oil and filter but seems a waste as it'll have to be done again ....

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