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Leeky · #21 16-08-10, 00:32

Nice work Andy.

That buckhead support rail is a nightmare to remove isn't it! Its the worst part of the whole job; I'm forever dropping bolts into the innards of the chassis, and then spending ages getting them back with my magnet!

You'd done very well for your first day!

ASTOBBS · #22 16-08-10, 22:15

Thanks Leeky,

started this morning with a proper fitting of the heater unit, the condesate drain flange is a pig aswell

So thats all in now, got the matrix fitted etc. etc.

and cracked on with the wiring, it simplifies down quite nicely, all in all there only ended up being 4 wires going through the bulkhead.

Pushed the contacts into the back of the aircon switch and made the connections

Ditto with the fusebox

I havn't removed any of the cars original wiring, instead adding large chunks of aircon wiring, so there are now 2x recirc servo plugs, 2x heater blower plugs, 2x heater controls plugs.

The non AC cars, don't use the green relay for speed 4 on the blower, just wired straight in, not really sure why.

Working under the bonnet, adding the white plug, I foud the original plug for the single rad fan, already has a supply from fuses 38 and 40, which are the very same fuses that supply feeds to the aircon fans etc. so i just tapped into them.

Two of the 9 contacts aren't used so I didn't waste anytime messing with them, just coiled them under the battery tray

So all in, that only leaves the 3 wires to the ECU, I changed my mind on them, was going to wire in the whole of the plug, but just added the 3 wires to the ECU side of the plug instead. Keep it simple.

That just leaves the wires from the bypass valve servo, and two more wires from the white plug to go through the bulkhead, I pulled them through a hole made in the side of the large grommit on the N/S of bulkhead.

Just got the dash back in tonight,by god thats a horrid job. Tomorrow, its put the dash back together, then make some sort of salvation on the coolant rail, to include the bypass valve. Get the radiator swapped over and add the condensor, and pipes, maybe get the compressor in, will have to see how the time goes.

Leeky · #23 16-08-10, 22:53

Thanks for the update. This is coming along really well!

So looking at it, non AC models don't have the hole in the bulkhead for the AC pipework? I really thought that would have just been blanked to cut down on production costs.

I feel your pain with the dash. It comes out much easier than it goes back in. The wiring makes it a pig of a job - I've done it loads of times, but I always forget to put at least one part of the loom in the right place, meaning I have to backtrack later on and sort it. lol.

ASTOBBS · #24 17-08-10, 08:16

thats right regarding the hole in the bulkead, I too thought it odd that they didn't blank it off, but when its put in context with the fact of non AC models having a massive hole in the roof instead, it seems minor expense in comparison.

ASTOBBS · #25 17-08-10, 22:23

Bit dissapointed with the progress today, had hoped to get further,

Had intended to get the inside back together first, but rain stopped play there, don't want the inside of the car getting soaked so went onto work under the bonnet.

Got the bumper off, and the radiator out, then got the engine bracket off.

Both of the aux belt tensioner pulleys, felt rough on the bearings, the original on my car felt horrid, I got a price of £50 last december when I changed the aux belt, but decided it could stay on the shelf for that kind of money.

Anyway I've managed to change the bearing in one this morning with good results,

Pressed the rivets out in the vice, and tapped it apart

Pressed the new bearing in

Put the rivets back in and peened them over again in the vice

Feels beautiful now, all for about £4. RESULT!

Got the replacement engine bracket in, which carries the compressor, WHAT A FIDDLE this took ages. But eventually got it in, and got the compressor bolted on, left the power steering pump loose at this stage to help with getting the new rad in.

At this point I decided to try and get the stretch of ac pipes from the heater unit to the airbox in, had to take a fair bit of stuff off to get them in, torque reaction mounting and bracket, it all takes up time, got them fiddled around in the end though.

Then the lower AC pipes, have re-used all of the orings, have smeered them in wellseal before fitting, finger crossed they wont leak!

Then it was onto the radiator and condensor, this was fairly routine but no less of a struggle, had to take the re-enforcing bar off (think thats the name, brain has gone dead)
to get the AC fan in. Have fitted a new dryer aswell.

Did the water pipes and electrical side next.

I'm having trouble with the power steering fluid cooler, had to bend it to get it around the fan, but now the bumper is hitting them. Have just left it for tonight will fall back on that tomorrow

Need to do some bodging on the coolant side. Need to get hold of a hose joint barb tomorrow to join the cut ends.

Leeky · #26 17-08-10, 23:02

Thats still very good progress mate, in the grand scheme of things this is progressing very well indeed!

Nice bearing replacement too.

matt-m · #27 17-08-10, 23:46

all them wires my god .....good progress though

ASTOBBS · #28 18-08-10, 23:49

FINISHED!

well almost, have yet to have it gassed. Would be nice if I could pressurise it with air to check for leaks before shelling out on having it gassed.

glad its all back in!

Leeky · #29 19-08-10, 00:47

You glad you did it still then?

They'll vacuum it out first, so if it doesn't hold a vacuum its unlikely they'll be silly enough to gas it mate - Just ask them to vacuum it and try and hold it to see if its leaking first.

ASTOBBS · #30 20-08-10, 12:50

Success! All gassed up and blowing cold. ECU side of things is cushty, £20 cash for gassing, as borat would say , very nice!