Having the build sequence roughed out helped me think through any dependencies; its all common sense + reference to existing knowledge from the Factory, other builds & online forums.
During the build I coloured each line to tick them off but removed the lot as a final check
( Green = Complete, Yellow = Work in progress, Red = Flagged)
Laterly used as a general to-do list
Donor Parts
- Diff: Clean & paint
- Diff: Replace shaft oil seals
- Diff: Replace pinion shaft oil seal
- Shafts: Clean & paint
- Shafts: Replace CV boots
- Rear hub carriers: Clean & paint
- Rear hub carriers: Replace oil seals
- Rear hub carriers: Grease
- Front uprights: Clean & paint
- Replace wheel studs x16 - needs 47mm studs
Take delivery
- Gearbox
- Zero Kit
Chassis on high stands (max 450kg)
- Panel: Seat back
- Under seal exterior rear axle well & floor panels
- Fit Differential
- Check seat belt attachment points are accessible & clean (photograph mounting points)
- Pedal box
- Master Cylinder
- Brake lines Rear Front
- Steering column
- Offer up Steering rack
- Panel: Drivers side tunnel & bulkhead
- Panel: Drivers side crescent
- Panel: Passenger side bulkhead
- Panel: Drill & prep all passenger tunnel panels
- Panel: Drill & prep passenger side crescent
- Rear suspension
- Rear shafts
- Rear discs, calipers & hand brake lines (hub nuts torque later)
- Front suspension - remember IVA boots
- Steering rack - leave ball joints loose!
- Front discs
- Hand brake - Check I'm using the top hole on the lever
- Swirl pot & bracket
- High pressure fuel pump
- Low pressure fuel pump/filter
- Prop shaft
- Carpet - O/S, Floors & footwells
Rolling chassis
- Lower onto wheels so the chassis is mobile
- Low pressure fuel circuit Front Back
- Clean & mount fuel tank
- Rear Panel - don't forget holes for spare wheel carrier
- Speed sensor bracket
- Fix gearbox mounting rubber
- Chassis loom
- Battery loom
Engine Prep and install
- Replace sump
- Thrust bearing/spigot
- Remove inlet manifold
- Remove exhaust manifold
- Remove thermostat housing
- Offer & check fit of new inlet/fuel rail/plennum
- Bell housing starter bulge adjustment
- Mount gearbox to engine
- Mount starter motor to engine/gearbox
- Oil pressure sensor
- Offer Engine/Gearbox to chassis
- Engine mountings
- Install Engine/Gearbox combination
Engine Services
- Plenum/Injectors and Air intake - clean & fit
- Idle Air Control Valve - My Direct mount
- High pressure fuel circuit
- Alternator
- Engine Loom
- Engine earth strap
- Horn
- Radiator
- Fan
- Cooling circuit
- Exhaust manifold - offer
- Oil breather pipes/filter
- Differential oil
- Gearbox oil
- Engine oil
Finishing
- Panel: N/S side tunnel
- Panel: tunnel top
- Adjust speed sensor
- Carpets - Seat back panel, N/S footwell, Boot
- Vinyl - Tunnel top & aux panel
- Front suspension off & onto axle stands N/S O/S
- Panel: nearside side panels
- Panel: offside side panels
- Front suspension final fit & torque N/S O/S - remember IVA boots & copper slip bolt shafts
- Fit Scuttle
- ECU, Fuse Box & Heater
- Fit Battery tray & pedal box cover
- Fit Nosecone
- Fit Bonnet
- Headlamps
- Front Indicators
- Rear suspension final torque
- Rear hub nuts torque
- Steering rack torque
- Lower steering column
- Front brakes & lines N/S O/S
- Tyres, valves & balance wheels
- Front Wheels
- Rear Wheels
- Torque suspension nuts
- Fill and bleed brakes (re fit/measure 43mm rear bolts & lock washers)
- Rear wheel arches
- Rear lights
- Boot cover
- Dashboard loom
- Dashboard
- Check loom - functionality - dash/lights/stalks
- Boot floor
- Manifold - final fit
- Bonnet Manifold opening
- CAT & Silencer
- Find the front nearside brake caliper spring & fit
- Nosecone grill
- Wing mirrors - cover the nuts, shrink wrap
- Rearview mirror
- Front wheel arches
- Seats, Seat belts
Engine first start checklist
- Check Diff has oil
- Check Gearbox has oil
- Check Engine has oil
- Check Cooling system has coolant de-ionised water + approx 30-50% antifreeze
- Check oil pressure
- Check fuel system - no leaks in LP or HP side
- Start
IVA
- IVA Prep - VIN x2
- Check torque page is complete
- Calibrate Speedo
- Configure ECU
- Align headlamps - roughly, hoping I can adjust during the test
- Align wheels
- HP Fuel pump - attach with metal/rubber not cable ties
- Gear knob
- Heater knob - remove Wiper motor & washer reservoir
- Brakes - check pads seated correctly & bed in/degrease disks
- Check all trims in place - no edges
- Insurance
- IVA Test - 30/5/2013 - Passed !
DVLA
- DVLA Registration & Tax
- Number plates
Post IVA & DVLA
- Steering wheel
- Windscreen
- Spare wheel carrier
- Weather gear; doors, half roof
- High level brake light
- Front mud guards
- Bonnet vents
- Badges - union jacks, GBS & Zero
General To-do list/notes - Feb 2014
- Half roof - done
- Rear wheel arch guards - done
- Bonnet locating pins - done
- Speaker high pass filter - done
General To-do list/notes - October 2014
- Re-paint wing mirror backs - done
- Check cooling system, thermostat, flush and refill anti-freeze - done
- Swap out radiator fan for large pusher - done
- Secondary ground line to block & chassis for the alternator - done
- Paint spare wheel retaining threaded rod - done
- Washers/waterproof windscreen to scuttle mount to avoid wet feet - done
- Grease propshaft UJs - done
General To-do list/notes - January 2015
- Replace timing belt - done
- Pedal box cover edge around brake fluid reservoir/scuttle runoff - done
General To-do list/notes - April 2015
- Radio headphone circuit - done
Post Scotland 2015 - Things to check/amend
- Rears rubbing the arches sometimes - done
- Windscreen chip - ignore - done
- Front number plate bracket - done
- Quick Rack - done
- Headphone circuit adjust - done
- Radio aerial double check - done
- Passenger foot rest - done
Post Barcelona 2015 - Things to fix
- Boot edge trim - done
- Silencer rattle - done
- Change headlamps - done
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