Project: Engine Recall

[4WheelDrifter]

Thanks to Ross and Laura for being excellent hosts, keeping us all topped up with food and drink.
What can be better on a nice sunny day than a little S2 tinkering with a few friends?
It was a shame the engine was so stubborn to get in and the downpipe put up such a fight. Or was it just because there wasn't enough daylight hours? We just didn't end up with enough time to get the Avant running. We'll just have to meet up again in March.

[s2_bo]

Thanks Ross and Laura, was a great day and we got a fair bit done, the vid is very funny too, makes me look like a overweight redneck truckdriver.

Big thanks to Ross for taking us all out for dinner!

Hope you get the rest done with out to much trouble.

[Ross]

Pics of the front bumper with the newly painted grills, courtesy of Sonic. Next, just got to get him to clean up the paintwork

Only problem now, is the bonnet grill looks tatty in comparison and needs to be done...

[Ross]

Also, cleaned out the breather system. As I had a complete spare system, I planned on cleaning up the old one and then replacing it. However, it was gunked up with loads of solid nasty stuff and check out the fire trap thingy on the left. So I decided to have a go at cleaning the one on the donor engine, which was much better - just the usual oily residue and the fire trap was in good condition. I soaked it in carb cleaner for about an hour and it looked much better (the one of the right).

All put back together now, definitely a job I should have done BEFORE the engine went back in! Other progress - starter motor is now in, and I've fitted the alternator and now need to take it back off to put the PAS pump belt on

[Ross]

Spent an hour cleaning up and organising the garage, and removing oil stains from the driveway... then couldn't help myself getting stuck in to fitting the PAS pump. Also replaced the "turbo coolant return to water manifold" rubber hose that is normally hidden behind it.

The big job to get done now is mounting and fitting the 034 Hi-Output coils, really struggling to find somewhere they can go without having to get a long set of HT leads made...

Done for the weekend, I keep popping out to the garage "for 5 minutes" and then getting dragged in for tea an hour later

[s2_bo]

Good Job Ross! im looking forward to seeing this when its done.

[s2driveruk]

looking good there Ross, it's great when it all comes back together, sorry I couldn't make it over...gimme a shout when you're planning to have another crack and I might be able to make it!

[Knight Rider S4]

The big job to get done now is mounting and fitting the 034 Hi-Output coils, really struggling to find somewhere they can go without having to get a long set of HT leads made...

:

Strut brace is the common place people go for ..no good there for you ?

[Ross]

Strut brace is the common place people go for ..no good there for you ?

Yeah it's really tight but I think they'll go between the ISV and ABS unit. Problem is two of the leads will be stretched a little there. Just nervous that a little bit of engine movement might cause a problem! I need to lift the coil cover and see if I can route the front cylinder wire a little straighter and get an extra inch or slack...

Might get inventive and try to bracket them a little lower, I've test-fitted them like that and it gives an extra bit of slack, prove mark's engineering skills as he is gonna put a bracket together

[terrybullwon]

Ross i have the same problems with my coils.

They are going here and i am going to make my own leads.

[Ross]

Well all credit to Mark's engineering skills I think we have a solution; this to be fitted tomorrow:

[Sonic]

Nice

[mark_s2]

Hope you don't mind Ross - finished the bracket for the 034 coils. Lte's hope they fit in the gap...

[mark_s2]

beat me to it...

[Ross]

It was too tight to get 5 in-line on the strut brace, they would have been jammed against the ISV lead on one side and the copper piping by the ABS unit on the other side.

I realised that the shortest leads would fit OK if 2 packs were located low down - they route under the intake and straight into the coilpack in this position. Then it looked like a pretty neat install if the others were just mounted directly above. The whole lot sits about 2cm forward from the strut brace to give clearance from the fuel lines.

Mark managed to make a very bad explanation of what I pictured into a reality

Will post up some pics of fitment tomorrow.