Installed insulation around the Fuel lines in the engine compartment

http://tedperkins.com/fuel_lines.htm

26 march 2005

Started installation of remote oil filter on 2200.

page is here

Recored radiator, assembled with new condensor and fans

http://tedperkins.com/2200_air_conditioning.htm

Feb 25

Installed Starter and heat Shield

http://tedperkins.com/starter.htm

Installed all cooling tubing aft of the water pump.

http://tedperkins.com/cooling_hoses.htm

Items to plan and and get for next weekend's work:
Heat Resistant sleeving to put around fuel lines.
Temperature sender for the coolant, M16x1.5
M5 Bolts for starter Heat Shield
Spark Plug insulation sleeves

Feb 19

Installed and mapped the low pressure leak lines for the Hydraulics

http://tedperkins.com/suspension_leak_lines.htm

Installed and mapped the high volume LHM return lines

http://tedperkins.com/high_volume_return_lines.htm

I installed the slave cylinder on the clutch

Spent much time puzzling over the throttle linkage and cables. I decided that the cable was stretching in its sleeve, so that for every 100 units of accelerator motion, I would get about 75 units of movement at the other end. I ordered a new cable, in hopes that that will resolve the problem.

25 GTi Driveshaft and Handbrake linkage

Pulled and cleaned handbrake linkage from 25GTi.

Measured handbrake pads, better thickness than I expexted.

Reinstalled handbrake linkage, and started adjustment procedure.

Reset right driveshaft with ear-bolts. Tightening down the locknut on the top of the bearing race is an absolute nightmare. Part of the problem is the shitty chinky stubby wrench I was using. The wrench had too much resistance on the return movement, so it ended up slackening the nut. So, I had to reach up with one hand and hold the socket in place on the return stroke, while turning the stubby ratchet with the other hand. Meanwhile I am on my back on a concrete slab that is about 30deg F. This car was made to be worked on by little french hands.

Front Steering Swivel - Right

Chased threads on new hub. packed new bearing with synthetic grease. Pressed Bearing into hub. Set brake disc with temporary anchor screw. Installed caliper, handbrake linkage. Attached handbrake linkage.

Pulled right driveshaft on CX25GTi (again!) to reset ear bolts.

Front Steering Swivel - Left

Cleaned outer half of caliper. Reinstalled caliper & torqued bolts down. Cleaned and greased handbrake caliper mechanism. Lots of brake cleaner and a wire brush!! Reinstalled handbrake caliper mechanism. Connected new handbrake cable. New fasteners.

Weber Carburetor

Cleaned and polished throttle cable linkage mount. Clearcoated the raw metal. Cleaned carb body a bit, not much surface junk since it was rebuilt relatively recently. Created and installed filter screen to keep jets from clogging. Installed carburetor, no control cables installed yet. New fasteners on all.

Page documenting the work.

Accelerator Pedal

While I'm under the dash looking at the just-installed clutch-brake assembly, I notice that the accelerator pedal assembly has some surface corrosion. Out it came. I disassembled it, scrubbed off the surface corrosion, and put a new coat of high-gloss rust-oleum on it. Packed pivot point with grease. New M8 fasteners

Hydrualic Clutch

Cleaned & sanded the rust off the clutch / brake pedal assembly. Repainted with gloss black rustoleum. Took clutch master cylinder out of lhm bath of past year and installed. New M6 fasteners.

Here's the page of the work on the clutch, and my description of its operation.

Starter

Not super happy that the guy who rebuilt my starter motor did not replace the wire from the solenoid to the motor. I decide to put some spiral wire sheath around it & hope for the best.

Used vise and hammer to tap end of cable to 90 degree bend.

I discovered that the long bolts to anchor the starter will not clear the HP regulator support. So, regulator support must come out to enable installation of through bolts. Rest of installation went smoothly. Direct-drive starter is very heavy and is a bitch to hold up for a long time while the bolts are getting screwed in. Torqued bolts to specs

Left powertrain mount

New 10.9 fasteners. Red locktite, torqued to specs. Ring nut on shaft to transmission not final-torqued.

Water Pump

Have to replace water pump with the one sent by Dave Burnham. Quick job. renewed gasket sealer a bit, gasket from first installation was in perfect shape. Used Dremel to abrade off corrosion and sedimentation from thermostat cover

HP Pump Drive

can now continue installation of HP Pump now that correct water pump has arrived. Reassemble HP pump shaft with paired drive belts to water pump. New M6 fasteners & lockwashers. Reused M7 fasteners on HP Pump mounts because of unusual length and mid-shaft nut design on fastener.

HP Pump drive

degreased, scrubbed rust and clearcoated 2-part pulley for fitting on camshaft extension. Scrubbed and painted metal parts of HP Pump shaft. Have to stop work pending arrival of 2-groove water pump pulley