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To make it easier fitting the 3 way hose I removed the inlet manifold, the throttle body was also removed, standard size for these are 64mm so I sent it off to be machined out to 68mm
Before:
http://i1250.photobucket.com/albums/...p/100_3882.jpg
After:
http://i1250.photobucket.com/albums/...p/100_3885.jpg
While I had the inlet manifold off I carefully enlarged the opening where the throttle body sits so it matches up to the work that had been carried out on the throttle body.
http://i1250.photobucket.com/albums/...p/100_3891.jpg
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I removed the fuel rail and took out the 4 injectors, I had these tested and they came back with a clean bill of health so I then had them ultrasonic cleaned
http://i1250.photobucket.com/albums/...p/100_3893.jpg
The fuel hoses to the fuel rail looked like they had seen better days so I replaced them to be on the safe side
http://i1250.photobucket.com/albums/...p/100_3898.jpg
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After I had fitted my hoses I then assembled it all back together with a new inlet manifold and throttle body gasket
http://i1250.photobucket.com/albums/...p/100_3892.jpg
http://i1250.photobucket.com/albums/...p/100_3902.jpg
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Great project mate. Have you still got the other pair of door cards you didn't fit?
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This project has come to a bit of a stand still although I have been tinkering with my other nova as well (83 xe)
Here it is a few years back with my old GTE and mk2 trip.
http://i1250.photobucket.com/albums/...p/100_0842.jpg
Anyways back to the van, as it had been sat for a while I gave it a full service, I know a lot of people use GM oil but it does seem to be expensive so I use Castrol GTX magnatec although I always use GM filters. I always put in an engine flush before and an oil additive after
http://i1250.photobucket.com/albums/...p/100_3917.jpg
My other xe seems to run better when I fitted NGK iridium plugs so I fitted 4 of those and treated it to some new HT leads as they had seen better days
http://i1250.photobucket.com/albums/...p/100_3911.jpg
The induction kit was filthy so I bought a K&N filter cleaning kit and cleaned it twice
http://i1250.photobucket.com/albums/...p/100_3918.jpg
I also changed the fuel filter (didn't take a picture of that as it isn't very interesting lol)
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I fitted the cleaned induction kit back and fitted a new blue hose from the induction kit to the AFM to match all the other blue hoses
http://i1250.photobucket.com/albums/...p/100_3976.jpg
I think some people call this a doughnut but where the AFM joins to the powercap/airbox mine had started to split but I found LMF Vauxhall had some new GM ones in stock so I bought one of those as well.
http://i1250.photobucket.com/albums/...p/100_3913.jpg
Few other goodies I bought, a new shiny exhaust manifold heat shield
http://i1250.photobucket.com/albums/...p/100_3908.jpg
Also was looking on ebay and found you can still buy new mk2 indicators. I bought both for £16 the pair and they were Lucas. I like fitting new parts when I can even better when there good quality and fairly cheap!
http://i1250.photobucket.com/albums/...p/100_3912.jpg
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Started tinkering with this again. Made a shelf up in MDF, glossed it black and fitted it in with blue carpet tiles to match the rest of the back of the van.
http://i1250.photobucket.com/albums/...p/100_4166.jpg
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The van had been lowered before I bought it (not sure how much, looks about 30mm) I wanted it sitting lower though and the shocks looked old so I bought a Bilstein suspension kit (shocks and springs). This lowers 60mm at the front and 40mm at the rear so the van sits a lot nicer now
http://i1250.photobucket.com/albums/...p/100_4035.jpg
http://i1250.photobucket.com/albums/...p/100_4074.jpg
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I fitted the front suspension back with new top mounts, support bearings and bump stops
http://i1250.photobucket.com/albums/...p/100_4036.jpg
I also wired brushed under the wheel arches and sprayed them all with spray on underseal
http://i1250.photobucket.com/albums/...p/100_4033.jpg
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While I was doing the nearside rear I noticed the rubber exhaust hanger was perishing so I changed all 3 for poly ones
http://i1250.photobucket.com/albums/...p/100_4072.jpg