My 3B to RS2 project

[newsh]

ABY rack now fitted and car back on its wheels

Now to fit the evo EM and turbo and look at the reverse IM!

[Error404]

sounds like you've been having fun John. How many knuckles still have a full covering of skin?

[newsh]

That job sucks!!!
I bet your knocked after that!

Yep, fooked, there was a point when I thpought it wasn't going to come out.. really glad I did it while the manifolds are off and the battery tray is now gone. Got an ABY rack being checked ready to put in

Also helped that I degreased the engine bay yesterday and also I've discovered nitrile gloves, my hands are actually ok

[s2_bo]

That job sucks!!!
I bet your knocked after that!

[newsh]

Went out this afternoon to do a quick job, take the rack out, how hard is that? Can't imagine how you'd do it with the battery in there ... absolutely knackered now

[newsh]

Nice job! Yes the engine is in the car, mmm, shall I take it out

[Error404]

good good
I used a linishing pad on the grinder, then a combination of high build primer and lots of elbow grease with the wet and dry to get it smooth, you'd be hard pushed to tell now unless you were really looking for it


Is the engine still in i take it? Hopefully you'll be ok with removing the rack as long as the yolk isn't siezed onto the pinion... mine was and i had to **** the **** out of it with a hammer from the engine side to release it.. no way I would have been able to with the engine in the way... helps if you release the collapsible section of the steering column under the dash

Gunk rhymes with junk
Never used APC but heard good things... Marina Clean is pretty industrial, so definately need to reprotect the paint with some wax or something afterwards, but it can't be beaten for cleaning power

[newsh]

I spent another hour with the angle grinder after those pics. All the remains are now ground off, just need some mastic and a bit of paint now.

Was thinking of either Gunk or some of that APC stuff? And my new Halfords 35 quid pressure washer. The rack has to come out now, at least I can pretty much get to it

Battery is homeless at the mo, have a tray to fit though..

[Error404]

PITA removing all the evidence of the battery tray, it's hard enough to get a grinder in there with the engine bay stripped bare
I'd treat that surface rust asap though. Did you weld in an ABY battery tray in the end?

Looks exactly like my bay before i tidied it up, the filthy **** gets everywhere

Try some POR15 Marine Clean, makes shifting it relatively easy work, still requires plenty of scrubbing though.

[newsh]

Some pics

Broken wires, sure I checked these recently ..


Mess


oil on plugs and rack


Oily pipes below where battery used to be.

[newsh]

Yes it might be coming up the hole in the cap where the level sensor swivels, I wonder if there's an O-ring in there?

I've got fluid up the back too, the 2 big engine bay loom plugs are wet, how does that happen? It would have to flow uphill maybe spraying from one of the servo pipes..

[Error404]

I've got a leak too, can't work it out, I'm sure it comes out of the top of the reservoir where the tip of the plunger sticks out
I checked all my lines over and replaced the reservoir when i stripped my engine bay out in the summer and no leaks from them.... The area around the reservoir is wet, but neither of the nipples on the reservoir are leaking... its doing my head in and dribbling sticky filth all over my lovely freshly painted engine bay

[newsh]

More stuff removed and tidied today under the bonnet, took out the last of the plastic rad shroud so I can get to the stat, PS pump and front knock sensor area easily.. The PS pump is where the main fluid leak is, no doubt as there's a lot of fresh oil on the underside of it and below. This was a recondioned pump which must have started leaking as soon as it was fitted Wonder if these's a fault with some other part of the system which is making it leak? All the low pressure fluid pipes to and from the reservoir have slow leaks..
Took out the dizzy cover and HT leads, catch tank and other stuff ready to remove the old servotronic rack which I'm going to replace with an ABY item.
Found the smaller of the 2 clusters of earth wires that bolt to the IM has rotted away where the wires solder to the tag, 2 of the 3 wires broke off as I was moving it and one still hanging by a thread.

[newsh]

sounds like progress is being made there John, mine was crudded up with tons of old ps fluid and grit etc from years of weeping on the t piece under the tray. Somewhere i have the part numbers from pirtek who remade all of mine if you need it...

happy New year btw

Doesn't really feel like progress as it's getting further and further from being a running car but yes, I've been meaning to do this for ages.
I think I need to sort the rack and pipework before putting any bits back on the car, anyway the DP needs a couple of bosses adding before the turbo and manifold go on.

[newsh]

What you going to do with all that space then?

Where have you decided on relocation?

Catch tank and coils

I've got a box cut out of an ABY to go in and a battery loom on the cards from Gav.