Cracked ZD30 head, what should I upgrade?

[Joseph Hardefeldt]

Firstly, thank you everyone for all for the great information on here, I've been lurking for a long while and really got a lot from all the threads. really appreciated.

Okay, so I've finally joined the club. My ZD30 2004 blew a hose while someone else was driving and they didn't pull over until the cracked head indicator was already lit. I went and let it cool, then filled the radiator and limped it home, it was pressurizing and started to heat again after about 5km of soft driving.

So presumption is top end is gone.

I have purchased a new head, from a local guy in Brisbane who runs a shop out of his garage, He pulled the new head down and rebuilt it, setting all the clearances and checking everything over for 2k, he said that he spent about 5 hours on it and mentioned that while you can buy these reassembled heads, bolt them on and have them fun, they are never right out of the box, so money well spent, happy to link to him if anyone is interested.

So the reason for my thread, I have a bunch of things I've been putting off and figured while I've got it torn down i might as well do some upgrades / PM's.

I got the ute about 5 years ago for 6k (an absolute bargain) and have done all the services myself since then, so am happy to spend about 6k on it. (already 3.5 k into the fix)

What i have already purchased and have ready for install:

• 3" PPD stainless exhaust, high flow cat only
• catch can - EGR blank already done
• XR6 intercooler
• New radiator
• New coolant hoses (silicone)
• New vacuum hoses
• New Engine fan (old one was cracked like crazy)
• Triple pillar pod - EGT + Boost, Oil temp, + one spare spot (thinking a dual Volt and water temp)

Options left to decide on:

• Stage 1 upgraded turbo
• New glow plugs
• Timing chain
• Water pump
• ECU Remap (the $500 swap out one)
• Upgraded air intake box
• New injectors
• boost controller

Also the last owner welded the turbo waste gate open or closed, so figure new turbo is a priority.

Anyway, given it was a cheap car, and only had one owner, i feel like i need to fix it up, i owe it to Harry (damn thing came with a name)

would be super happy for any feedback on what i should get / do while its pulled down.

Thanks in advance!

 

[Boogieboots]

I had the crazy cracked fan on mine too. How are you plumbing up the intercooler? Is there a kit that you have found?

 

[Joseph Hardefeldt]

I had the crazy cracked fan on mine too. How are you plumbing up the intercooler? Is there a kit that you have found?

Hey mate, no standard kit, I'll do a similar installation to this thread modded xr6 intercooler into the 03 str

 

[Erick]

Spend $120 and get an engine guard. Temp monitoring/alarm. Would possibly saved u $6 g. Then u can use ur spare pod for something else. Wins all around

 

[Joseph Hardefeldt]

Thanks Erick! Had a look and that seems like a great add on, will purchase one. Doing the water pump too, might as well since its all apart.

 

[dattorob]

For intercooler i used Forefront industries BIG front mount kit , worked out really good. Also in house fab do a good snorkel and sealed cold box so you can run a decent pod filter. Basically if you're chasing performance you'll be working off the recipe provided by BAET (Border Automotive Engineering and Tuning | Remapped ECU Specialists) for the various stages.

e.g.

Stage 2 Mail Order Tune​

Our Stage 2 Tune is designed for cars with the following modifications:​

• Aftermarket turbo back exhaust system 2.5 or 3.0 inch
• Aftermarket turbo capable of running 20-21 PSI reliably
• Intercooler. Can be top or front mount. If top mount needs to be a decent installation with a good seal around bonnet scoop.
• Upgraded airbox to allow for more flow (and to take some stress of turbo)
• Boost controller set to 20-21PSI
• Boost cut defender to rescale boost levels that the MAP sensor sees to keep boost cut functionality but rescale it

Stage 3 Mail Order Tune​

Our Stage 3 Tune is designed for cars with the following modifications:​

• Aftermarket turbo back exhaust system 2.5 or 3.0 inch
• Aftermarket turbo capable of running 24PSI reliably. We have used the high flowed turbo from GCG previously.
• Decent sized intercooler. Can be top or front mount. If top mount needs to be a decent installation with a good seal around bonnet scoop.
• Upgraded airbox to allow for more flow (and to take some stress of turbo)
• Boost controller set to 24PSI
• Boost cut defender to rescale boost levels that the MAP sensor sees to keep boost cut functionality but rescale it
• Bigger injectors +30%

 

[jonot]

Firstly, thank you everyone for all for the great information on here, I've been lurking for a long while and really got a lot from all the threads. really appreciated.

Okay, so I've finally joined the club. My ZD30 2004 blew a hose while someone else was driving and they didn't pull over until the cracked head indicator was already lit. I went and let it cool, then filled the radiator and limped it home, it was pressurizing and started to heat again after about 5km of soft driving.

So presumption is top end is gone.

I have purchased a new head, from a local guy in Brisbane who runs a shop out of his garage, He pulled the new head down and rebuilt it, setting all the clearances and checking everything over for 2k, he said that he spent about 5 hours on it and mentioned that while you can buy these reassembled heads, bolt them on and have them fun, they are never right out of the box, so money well spent, happy to link to him if anyone is interested.

So the reason for my thread, I have a bunch of things I've been putting off and figured while I've got it torn down i might as well do some upgrades / PM's.

I got the ute about 5 years ago for 6k (an absolute bargain) and have done all the services myself since then, so am happy to spend about 6k on it. (already 3.5 k into the fix)

What i have already purchased and have ready for install:

• 3" PPD stainless exhaust, high flow cat only
• catch can - EGR blank already done
• XR6 intercooler
• New radiator
• New coolant hoses (silicone)
• New vacuum hoses
• New Engine fan (old one was cracked like crazy)
• Triple pillar pod - EGT + Boost, Oil temp, + one spare spot (thinking a dual Volt and water temp)

Options left to decide on:

• Stage 1 upgraded turbo
• New glow plugs
• Timing chain
• Water pump
• ECU Remap (the $500 swap out one)
• Upgraded air intake box
• New injectors
• boost controller

Also the last owner welded the turbo waste gate open or closed, so figure new turbo is a priority.

Anyway, given it was a cheap car, and only had one owner, i feel like i need to fix it up, i owe it to Harry (damn thing came with a name)

would be super happy for any feedback on what i should get / do while its pulled down.

Thanks in advance!

Hi @Joseph Hardefeldt. Where did you get the head from and also have you been happy with it?