Productive weekend - she runs again !!!!

[Martiny]

Had a productive day / weekend on the FD

It started with my shock realisation that the 323’s MOT is about to expire. So I set to replacing exhaust, belts, etc on that. On the 7, I am in the process of an engine swap, and some of you may have read that I had snapped stud for the water pump.

I was loath to tackle the job of sorting out this problem, not really knowing what to do. So, while I was waiting for some engine cleaner to dry on the 323, I thought “mm, I’d better spray some WD40 on that broken stud – might ease it up a bit”. So I grab small screwdriver to clean it out with first.

SURPRISE!
What I thought was a snapped stud, was in fact, just dirt, which happened to be the same colour and shape as a snapped stud !! Who hoo! All I had to do was clean it out, and smarten up the threads with a tap.

PROGRESS.
Well, the 323 is nearly ready for it’s MOT, so I cracked on with the 7. I carefully put in a new stud for the water pump. Put loads of grease on the studs, and fitted the pump. Then I discover the 2 electrical plugs. A bit of a pain to fit them afterwards, and, of course, one of them broke its wire off, right at the plug. So I had to remove the water pump to get access to the wiring, and solder the plug on again, then re-fit water pump (I have put that pump on about 8 times for one reason or another, I am getting really good at it now!)  Cracked on all day yesterday from 8 ish… fitted the Alternator, Air pump and belts, Water hoses, AST, Battery tray, etc, etc.

ECU WIRING
Another job I was dreading was pulling that loom through for the ECU, and how will I get that huge grommet to go nice and flush on the bulkhead? After all, you cant get your hands down there, all the ABS malarkey is in the way. I taped up all the plugs and loose wires so it would go in smooth. Then I tied a piece of ski rope and passed that through the hole – this is so that I could pull on it GENTLY while I tried to push from the engine compartment side. I put some dishwasher soap all round the grommet. I managed to get it through, I think in a few minutes, and just used a screwdriver from above to gently slip the grommet in. I was well pleased, and I think I had a cuppa and a break to celebrate !

WILL IT START?
I had this funny feeling… so I made sure I knew where the fire extinguisher was, and I read the instructions……..
Battery all charged up, and I fit it, and sort out the wiring, ( I thought). Fill up Oil, coolant, and PS fluid. Leave plugs out for now ! So I get in, turn on, and there is a faint, constant beep – not normal. And the starter wont turn – in fact I don’t hear any relays click. Check all wiring…. Ah, what are those 2 plugs for, lying next to the LH headlamp? OH! – these are supposed to plug in to the bottom of that fuse box on the + battery terminal!  Plug in, switch on, click click, and the starter turned. So now I get the NEW plugs I bought for the shagged Engine, they were full of crud, but I didn’t bother cleaning them. The Battery is a bit old, so I bring up the 323 and jumper cable to the REX. This means I have to go round the back of the REX to get between the engine and the drivers side. Anyway, I crank it  a bit , and --- nothing, sounds like there’s any compression. So I put a little pipe on the boost gauge feed on top of the manifold, and put some atf down there.

FIRE!
I give the key another go, and I hear “BZZZT – FRAZZLE FRAZZLE” ------ ITS ON FIRE !!!!!!!!!! I rip out the key, run round the back of the car, whip off the jump leads, and I see fire coming up from the gearbox. Grab extinguisher, and dive under the car, and WHOOOSH – white powder and fire out. I realise the battery is still connected, so I fumble with a spanner and whip the connections loose.

What have I DONE ! ?
Gloomily, I consider a fried ECU, burnt wiring , and who know what else must be damaged. Hang on, though, the flame was coming from…. The starter! Burnt out solenoid? Burnt out windings? I have a look under the car, and what I discover is that the insulator on the + wire for the starter is burnt – and that’s all! It must have somehow shorted to earth when I was cranking. So I tape it all up, and bend it a bit so the wire goes away from earth. (ordering new insulator).

TRY AGAIN
Crank some more, full throttle, no throttle – each time crank for about 15 secs. It seemed to WANT to start with no throttle.  But.. now I hear a gurgling noise….
No big deal, the oil feed for the turbos was loose – I tighten it up. More cranking.. oh! What was that? On that last try I thought I heard it wanting to start!  So I leave it off for  good minute or 2, give the starter a chance to cool.

No throttle, just crank crank crank ……. Sounding better, sounding better…crank crank, crank……..Vroom ! on one Rotor Vroom! Other Rotor clears!!! BEEEEEEEP – low coolant, so I top up with it running. Check everywhere for leaks.

S H E ...   L I V E S ....   A G A I N  ....   WHO HOOOOOOOOO !!!

She got up to temp, and I switched off, and started packing up. Started it to move it, and once it started, squelch squelch squelch ?? I switched off, and the oil is pumping out from front left. I think it’s just an oil cooler line loose. Cleaned up the driveway, and put her away… will look another time.

So, I am well pleased with the progress on the weekend !! My poor little boy hardly saw me, so I don’t think there will be much progress this coming weekend!

[Archbish]

SKILLS DUDE!!!!  Nice one - must be an awesome feeling!  Well done

[probedb]

Nice one Martin, glad it\'s running

[noyzboy]

Good News.
Hope to see you on a few Autosolos with it in 2008.
Martin H

[Martiny]

more progress...

I found the oil leak - there is a little clip that connects the oil lines to the oil cooler/s, I had not connected this correctly.

now fitted Intercooler, air box, etc... just a few covers to go on, then its off to MOT!!  Yay!

yes, Martin H --- I will be back !!!

[probedb]

Awesome news matey

[ianelvar]

I got caught out with that one myself! Nicely done

more progress...

I found the oil leak - there is a little clip that connects the oil lines to the oil cooler/s, I had not connected this correctly.

now fitted Intercooler, air box, etc... just a few covers to go on, then its off to MOT!!  Yay!

yes, Martin H --- I will be back !!!