488 replies to this topic

[fezzasus]

Boot release

 

My boot cable has been ruined by a combination of heat and rain, which melted the outer plastic cover then allowed the inner part of the cable (coiled metal) to corrode and stop the wire from moving. I replaced this with a new run of the sheath and cable, but made the mistake of using a screw-clamped end on the boot release handle. This popped off three or four times, leaving the boot completely unusable until I could jack the car up and reach the control cable on the latch.

 

So I bought a brass solder end, fitted it to the cable end, splayed the cable out to stop it from backing off, dunked it in flux, then soldered with a blow touch. Needed a bit of cleaning up with a file but is working fine now.

 

 

PCV system

 

Whist swapping some bolts on the undertray, I took the opportunity to check the PCV filter is working. I was pleased to see that there wasn't any buildup of oil on the intake (note, shown without the rocker cover to Provent pipe connected as I had to disconnect to remove the air filter)

 

 

 

[fezzasus]

Treated it to some gaskets.

 

Cam blank

 

 

Exhaust gasket

 

[fezzasus]

New ground terminal clamp for the battery, old wire had frayed at the crimp connector. Hopefully the new heat shrink covered post terminal will be more robust

 

 

I use an Alpine head unit with an Imprint processor, this compensates for the shoddy placement of the rear speakers and balances in the front speakers i've fitted to the outside air vents in the dash. Previously this Imprint processor has been mounted under the dash, but I didn't like the cable routing and wanted to shorten everything to reduce the weight penalty.

 

I've moved the alarm across by 4 cm (self tapping screws) to fit the Imprint controller behind the VX220 badge, i'm going to use C-clips rather than rivets to give easy access. The Imprint needs to be connected to a laptop running the alpine software and connected to a microphone to configure it (unfortunately, this needs doing each time the battery is disconnected).

 

[fezzasus]

big MAINTENANCE update

 

Tried to take the car to Brighton about a month ago. This was the first 'long' trip I've done in it since fitting the new engine and wanted to see if I was going to have any problems before Le Mans later in June...

 

I had problems.

 

About 80 miles into the journey I hit Chichester traffic and the car died, would only start with my foot on the accelerator and even then would die quickly. The next few hours showed me that the time the car would run for was effectively proportional to how long it was left to cool down.

 

A few theories from this:

 

- Uprated fuel pump was putting more heat into the fuel and causing vapour lock in the fuel rail

- metal overbraid fuel lines were picking up heat from the engine bay and causing vapour lock in the fuel rail

- old coil pack was leading to poor spark when hot

- spark getting blown out

- dodgy grounds

 

So to cover these, I have:

 

1. Fitted a 48 L long range fuel tank. Idea here is that there is a greater thermal body to cool the fuel (thanks Joe)

 

2. Firesleeved the fuel lines

 

 

3. Replaced the coil pack with a new NGK unit

 

4. Checked spark plugs, have correct discolouration. Will consider gapping them.

 

5. Check chassis ground points.

 

Both front and rear chassis ground points had spinning rivnuts. My car stereo also develops interference after a few minutes of use (wiring diagram says this is a front ground issue). I cut out both spinning rivnuts and replaced. This was easily the worst job i've done on this car. The front point required me to position a mirror to aim the dremel in the right location, while the rear point required a flexible dremel head. Ribbed rivnuts were used with a bit of loctite 660 to minimise chance of spinning. Finally lots of general purpose grease was used to prevent any corrosion.

 

I also fitted a new crank sensor and replaced the gear cable firesleeve with tighter fitting material and silicone finishing (photo shows new compared to old)

 

 

So hopefully that's fixed it. Any other ideas?

[CHILL Gone DUTCH]

What fuel pump is it

[fezzasus]

DW65a

 

http://www.deatschwe... Tech Sheet.pdf

 

Is a drop in replacement for the OEM pump, unlike the others which all require modifications. specs comparable to a Walbro 255 but quieter

[alanoo]

Hum... I'm sure I have read something similar a few years ago on the french forum... will try to find it again

[fezzasus]

Would be very much appreciated

[fezzasus]

This might have something to do with it too. Now swapped for the equivalent Delphi unit

 

[alanoo]

Could make sense...

 

I've spent some time checking 40 pages of topics on the french forum yesterday without finding it again, but I will ask in the private section, maybe someone will remember it

[Rosssco]

Are you running an external crank sensor? I am, and I had initial misfire issues. One of the things I changed was the crank sensor (so no idea if it was that), but I also added a small washer to space the sensor back from the mounting position, as the original was marked with the new timing wheel. Works fine now.

[gaffer1986]

Your issues sound similar to when my crank sensor plays up.

[fezzasus]

Could make sense...

 

I've spent some time checking 40 pages of topics on the french forum yesterday without finding it again, but I will ask in the private section, maybe someone will remember it

 

efforts are appreciated none the less.

[fezzasus]

Are you running an external crank sensor? I am, and I had initial misfire issues. One of the things I changed was the crank sensor (so no idea if it was that), but I also added a small washer to space the sensor back from the mounting position, as the original was marked with the new timing wheel. Works fine now.

 

 

Your issues sound similar to when my crank sensor plays up.

 

Thanks both, seems like the crank sensor was worth changing. I didn't see any marking of the sensor from the external crank trigger wheel, but read a lot about crank sensors (particularly GM ones) developing faults when hot. Fingers crossed I won't have to worry about this again.

[fezzasus]

Done

Electrical

- change coil pack to NGK branded item, stretched coil springs (also moved from three piece to one piece springs which in theory is lower resistance and gives a better spark - assuming this was an issue)

- gapped spark plugs to 0.7 mm (still SAAB oem plugs, however colour seemed okay)

- replaced crank sensor

- replaced front and rear rivnut grounding points (both were spinning), cleaned up interfaces, greased.

Fuel

- Changed to 48 L pro alloy tank, in theory giving greater thermal mass (more fuel) which should mitigate against vapour lock from fuel heating due to pump discharge/cycling

- Firesleeved fuel lines and finished with silicone wrap (stop vapour lock from engine bay transfer through fuel lines - expected to be greater with metal overbraiding)

- tidied up fuel carbon canister hose pipework and replaced pipe damaged by SC belt.

Thermal management

- fitted new firesleeve (tighter fit) to gear cables, finished with silicone wrap.

- wrapped exhaust u bend, made gasket for cat section - exhaust interface

 

To do

- make gasket for cat - manifold interface.

- wrap cat section by manifold

- wrap car for Le Mans

- fill it up and see if it works!

 

Let's hope the weather is good this weekend

[Acidpopstar]

Blimey Tom that's a lot of work. Really hope it's fixed your problems and that you have a good trip Sent from my iPhone using Tapatalk

[navx]

What wrap are you doing? The Cadbury paint scheme was awesome.

[fezzasus]

The purple paint will remain, but I fancied something different for Le Mans this year. I thought british and supercharged, and ended up with this:

 

 

Good news is that the car seems to run fine. Took it for a 100 mile run yesterday and was faultless, other than intermittent stereo interference, which I guess is a fault..

Edited by fezzasus, 11 June 2017 - 08:30 PM.

[The Batman]

i have to say.......... wraping cars isnt one of your talents

 

 

[fezzasus]

Completely agree, I ran out of time and hated every minute

Edited by fezzasus, 11 June 2017 - 08:41 PM.