Time I pulled my finger out

Thought I had a picture of the fatigue cracks….

When I tapped that clean area, the whole piece fell out :eek:

the other side was cracked but not as bad,


I only removed it as I remembered seeing a worse one that Lee and Gaz were working on at Zedshed HQ

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Mazza said:
... I only removed it as I remembered seeing a worse one that Lee and Gaz were working on at Zedshed HQ...
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That was mine Malc:whistle:
 
Oh yes ,,,it was disintegrating :eek:=))
 
As you can see the rocker cover and air intake plenum are in a sad state.
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On removing the air plenum I found all the vacuum lines dry rotted and some of the larger pipes were like jelly
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so vacuum lines replaced along with the oil separator. Also refurbished some brackets that are hidden under all those lines.
 
While having a clean around the vanos covers I noted a cap head missing or so I thought. Turns out all the cap heads were loose and a stud minus the head.
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pleased there were was no oil leaking past the solenoids
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when my engine was rebuilt I think someone must have been nosey as there were no gaskets there, just some blue gloop. New ones from the dealer were silly. For a few quid and a therapeutic half hour
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New high tensile cap heads were cheaper from Kay’s or bolt world. Used some blue Loctite prior to torquing them down to 10nm.
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New rocker cover gaskets held in place with a few dabs of blue Hylomar at the half moons and creases.
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unfortunately there was bound to be a knackered thread but thankfully in a easy spot to insert a helicoil.
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Air plenum and rocker cover were painted with this stuff https://amzn.eu/d/02VSJuVk
I gave the parts an initial heat treatment with a large cardboard box and a hair dryer, made a makeshift oven. It was to give the finish a chance as the air plenum is a bit of a fiddly pig to fit for the first time. Any way the results don’t look to shabby.

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Back down stairs we go. The front bumper grill was cracked and missing a few bits. A replacement from the dealer is a bit eye watering for a bit of plastic.
The plastic frame was ok so I cut the rest out and hot glued some black aluminium mesh I purchased from Amazon. The frame fits over some pegs on the bumper which go through the frame and mesh then some star washers clip over the pegs securing the whole lot in situ. We will see how it holds up. Ignore the dirt on the mesh, looks better in the flesh.
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Abit messy behind but functional.
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Althulas said:
Back down stairs we go. The front bumper grill was cracked and missing a few bits. A replacement from the dealer is a bit eye watering for a bit of plastic.
The plastic frame was ok so I cut the rest out and hot glued some black aluminium mesh I purchased from Amazon. The frame fits over some pegs on the bumper which go through the frame and mesh then some star washers clip over the pegs securing the whole lot in situ. We will see how it holds up. Ignore the dirt on the mesh, looks better in the flesh.
View attachment 357721
Abit messy behind but functional.
View attachment 357723
Click to expand...
This reads like T-Tony fix. I bet he’s up there, approving.
 
It’s all looking very splendid work and time consuming*. A very interesting thread.
*keeps you out of trouble! 🤣
 
It’s been a while again lots going on plus some forward and backward steps 🤬gremlins.

First off moving some stuff out of the car and found this:rolleyes:

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so off with the air plenum again, all vacuum pipes definitely changed now🤦
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while replacing the tensioner another setback.
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Oil filter housing removed
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A 8mm helicoil installed using the back plate of the old tensioner bolted in situ to guide the drill bit. Forgot to take a pic of that bit.
While the oil filter housing and Alternator were removed it gave an opportunity to clean them up.
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All now reassembled.
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New pricey boot replaced.
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I had completed a full service and was running the car to warm up to check for any oil, water and fuel leaks. After the car had warmed right up, all was looking well. Then the engine got very lumpy and cut out and would not start without any throttle. I managed to get my code reader to read for once recording a 07 code
Inductive sensor on intake canshaft.
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First thoughts was the camshaft sensor but while I stood there over the engine bay I could hear a ticking noise coming from the intake solenoid cover. Inspecting the connections I noted a bulge on the side of the connector. Disconnecting it made the ticking stop. Recalling one of Pingu videos covering the subject of Solenoids I removed the intake solenoids and desoldered the red and green wires. Checking for continuity I discovered that one of the diodes must have blown in one of the circuits, fortunately both of the solenoids have good continuity across the contacts and click strongly while testing with a 9v battery after a thorough clean.
A bit of dremeling love with application of a soldering iron and heat gun to break down the rest of the plastic cleaned the wiring up ready for replacement diodes.
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I found a file on Thingverse for replacement covers and uploaded those to a 3d print company in Bicester for printing off at a reasonable sum. Replacement Diodes on order. So awaiting to resolve this issue before refitting under trays and a few bits and that should be all of the mechanicals completed.
 
It much of an update, not the professional job of soldering but everything works as it should.
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3D printed cover from a company in Bicester
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sealed together with epoxy
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new seals installed, although the old ones looked in great condition but it was a night and day bugger of a job installing the solenoids after changing the o’rings
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I still have this annoying issues of chasing down the communication issue with my code reader. It’s taking some time going through the wiring which is intact. I did take the DME out to have a look under zoom on the the phone the circuit board shows no sign of damage and can’t see any blown mofets etc. I have a few other things to check before sending the DME off for a service.
I couldn’t resist a cheeky drive around my village though, the engine purrs like a kitten.
 
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