Some more progress

Today with the help of my son Hamish, we have managed to get the following done in the list.

Day 1 Day 2 Day 3 Day 4

  • Remove existing MegaSquirt relay board, and existing wiring for EFI sensors Done
  • Fit EFI fuel filter under the car and connect hoses Done, removed and painted the filter housing as it was crappy Refitted all done
  • Remove standard engine driven fuel pump and fit blanking plate
  • Fit new 30PSI fuel pressure sensor (for PWM control of fuel pressure)
  • Fit new injector to throttle body Done. Removed it to make sure bottom ‘O’ ring was sealing, had problems with this in the past causing erratic fuelling as it was dribbling all the time. I’ll perform a leak test when I get fuel pressure up.
  • Fit new solid state relays (SSR) for PWM control of injection fuel pump and radiator electric fan
  • Clean and paint corner of bulkhead where brake fluid has removed paint and caused surface rust. Have obtained correct ‘Indigo’ blue paint in a can.
  • Finish fitting new Bluetooth radio Done. Played many tunes on it today!
  • Fit new relay and fuse block,
  • Wire new EFI harnesses to relay/fuse blocks and to sensors
  • Fit MS to bottom of dash rail using nut inserts (more secure)
  • Test and set-up PWM for both fuel pump and radiator fan control
  • Fit new windscreen washer bag to hang under the R/H fender and connect it up
  • Relocate power brake booster backwards by ~ 2″ to allow for a cold air/filter box to feed the MAF sensor that will be fitted at a later date. Removed, waiting for me to make new 3/16″ pipes and new brackets
  • Replace the Cooper ‘S’ discs and pads Removed discs and ultrasonic cleaned calipers
  • Replace with new and paint both L/H & R/H top suspension arms 1 done 2 done
  • Replace rear competition bump stops with standard bump stops Done
  • Check rear wheel brake cylinders for leaks and also that they are 5/8″ bore. Found one cylinder seized, replaced both sides, as well as brake shoe springs and adjusters.
  • Fit new brake hoses. 1/2 done
  • Fit the new heater Bench tested to make sure it works… it does
  • Fit the new boot brackets and make a boot board to fit on top of these brackets Bought marine ply and carpet to make it. Also trial fitted brackets. Brackets painted car colour (indigo) and made cardboard pattern of required boot board size and transferred this to 12mm ply and cut-out with jigsaw. Fits like a finger up a b**.
  • Get wheel balance and alignment
  • Fitted new roof mount aerial… what a PITA!
  • Continued to feed my ultrasonic cleaner various greasy/dirty bits
  • Fitted new black accelerator cable, so as to get rid of crappy yellow one
  • I couldn’t sell the NGK spark plug leads so I obtained some genuine NGK 90 degree plug ends and fitted them  to the shortened NGK leads. Looks a lot better as leads are closer to engine.
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Modified NGK (Audi A3) spark plug leads with 90 degree plug ends
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Ryco Z199 Filter and holder
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Filter fitted to Rover EFI holder

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