Ian's build thread

[ian360]

Hi everyone,
Starting a build thread so I have somewhere to ask all the questions I am going to need answering.
So started the strip down this weekend - pleased with how it went with no swearing or breaking any bits - few scraped knukles though. Have both doors off, the bonnet and boot, roof, bumpers front and back, seats, seat belts, centre console and front and rear lights.
First picture - no comments on the space please, i know it's tight!! I'm borrowing a garage as mine is already housing another car.


Here's what is left of the interior


So first question - pulling the wiring loom from the rear of the car there are some wires that disappear through the cabin floor(on the left hand side of this picture) and also into the sills just where the seat belts anchor. I've marked them and disconnected from the main loom - will their whereabouts become apparant when I remove the body? Can't see what they are supplying?

[mrjingles705]

The ones by the doors are, i think, the ones connected to the door open sensor/trip switch. The one through the floor ... Id thats the one in the second pic, it's the room to the fuel pump and rear of the car. All will become clear as you strip the access the panels away

[gwnwar]

The one through the floor might be the second O2 sensor wire that goes to the exhaust pipe. Like mrjingles705
said one into panels for door switches..

[ian360]

Second post (hope this is correct way to do this - I'm just replying to my own earlier post?)

So this weekend removed the front trim, steering wheel and column, front facia dash and air conditioning housing. Only real issue was a stubborn steering column release bolt. So i am now left with this

Question please - passenger footwell revealed two electronic boxes - pretty sure the left hand side one as we look is the ECU. What is the other one? And assume I unclip unbolt and put somewhere safe for later?

Thanks
Ian 

[Stiggy]

That's the ABS module on the right of the ECU. The main battery cable that goes through the floor near the rear bulkhead is attached to the PPF and runs to the Alternator. This can be left attached whilst removing body if you push the cable through the floor. Ignore the 2 pin plug (white with 2 red wires) next to the hole in the floor, that is just for boot aux power and heated rear window.

[ian360]

Quick question please - as can be seen I have removed most of the interior including steering column. Any tips for a quick way to get this put back - I think I need to move the car and will need steerage!! If at this point it is more trouble than it's worth might look at alternative options(?)

[ian360]

Quick question please - as can be seen I have removed most of the interior including steering column. Any tips for a quick way to get this put back - I think I need to move the car and will need steerage!! If at this point it is more trouble than it's worth might look at alternative options(?)

[miket]

Not quite the full answer/s you're after I'm afraid, but:-
1. The front wheels can be turned (in the steering sense) by manually pushing/pulling at them - albeit hard work.
2. Once the shell's off the column looks like it could be easily re-inserted without actually mounting it on any brackets and used 'loose'.
3. I got some skates/dollies and they've been great.
Good luck.

[ian360]

I have somehow managed to get where i wanted to be by Christmas and have the body removed from the sub frame. Quite pleased with that achievement, but now the real issues look like they will start! I am likely going to be asking loads of questions, certainly on the mechanical side, and appreciate in advance any help. Please excuse any incorrect descriptions, or if i'm stating the obvious - this is all new territory for me.
So being faced with a rolling PPF, the decision is what to do next - just wash off and wire brush or go for a more thorough dismantle and rebuild? How bad does the sub frame look in anyone else's opinion - there is a lot of rust but maybe not that bad for a 16 year old car. Will most of this brush away and then a paint to improve?


Also first look over the front end and there seems to ba a lot of oil on the gearbox, but on the top. I would guess this is a leak onto the cover, rather than a leak from it which i would expect to see underneath? Is that incorrect and any suggestions as to where this oil could be coming from, or where i should start looking, and what about fixing it?

Also a lot of oil around the gear stick base. Again is this normal in this age of car?

When seperating the body two final connections i had missed were the brake lines to front calipers (i know pretty obvious now) but both sheared off at the caliper at the point circled in this picture. Is this a simple replacement or a more serious issue, such as completely ruining the caliper which will need replacing?

Thanks

[gwnwar]

On the PPF a lot comes down to money.. I would at least have the subs and running gear blasted. If the bushing are tight you can leave them be. Having it blasted will save a lot of time and do a better job then a wire brush.. When clean you can prime and paint right away.. The oil on rear of engine could be from the CAS, cam cover or head gasket
The lower shift boot on the trans needs replacement while you are at it pull the shifter and check the plastic bushing on lower end of the shifted it pops on.. Fill the turret (were shifter goes) with trans fluid 80-95cc
before installing shifter.. Don't over torque the small bolts. With the caliper.. brush the rust off by fitting and soak it with JB Blaster or the like use easy out to try and remove..
If you are going to wire brush wear safety glasses..

[ian360]

thanks for your reply gwnwar. Time and money are not the issue, but ability certainly is and i was cautious about dismantling and having loads of bits and no way of putting all back together. Already spotted my previous post talking about gearbox when i think it is actually transmission cover?! However, it might be more fun to see where we get to.......
Could you explain what the CAS abbreviation is - think i know but want to be sure.
I think the calipers will come off reasonably easy - it was more that the lines sheared at that bolt on seperation and i don't want to waste time cleaning up what i have if in fact this has rendered them useless?

So now some more research to dismantle the PPF - any tips or advice I should be looking for would be appreciated in the interim.

[gwnwar]

CAS cam angle sensor. on back of head. it has a Rubber O ring to seal.. it will only go in/on one way as the ears are offset. Mark its location before removing.(1bolt).. Easier to do with cam cover off.. Rotating this is how you set your timing.. What year and size engine are you using.. I would not waste my time with a wire brush.. You might find a shop that will blast it all together in front and rear sections. If you do take it apart plastic baggy parts and were they go.. draw pics helps,, take pics..

[miket]

Ian, Re. wire brush vs dismantle & coat: As a complete novice, I had the same concern about how far to dismantle. I was aiming to keep costs down on my first build whilst I gained experience and found out if kit-building was going to hold my interest - so I de-rusted & painted. I've found that, with the help of this forum, I could have happily dismantled further and been fine. However, every task takes an inordinate amount of time the first time I come to it, so for the moment I'm glad I didn't add to the tssklist. When I've successfully completed I may well wish that I'd gone the other route.

"CAS" refers to the Cam Angle Sensor O-ring - a relatively common source of leaks.

I would have thought the callipers would have survived and the pipe damaged, but you'll have to inspect the calliper surfaces one it's dismantled.

'fraid I'm not in a position to advise on ppf dismantling, but it's cropped up in other threads.

[ian360]

For better or worse I decided to take the plunge so spent yesterday removing the exhaust, seperating engine and transmission and removing engine. That is all now wrapped up to deal with on another day in the future, so now left with this
Time will tell if this the right decsion, i did find this reasonably simple following all the threads and manuals and actually didn't encounter any problems. I doubt it will keep being that way. Next plan is to dismantle the rear sub frame....

gwnwar - it's a 1998 1.6 engine.

miket - thanks for your reply. Hope i made the right decision!!

[gwnwar]

With the PPF to diff.. soak the long bolts good. on the front bolt on diff end it pushes up a sleeve into the spacer that the top nuts are pressed into.. When you remove the front bolt the sleeve is designed to drop down out of the spacer but will most likely be rusted in place. take a wire brush to it to remove rust and soak it good..
Check this..
mevowners.proboards.com/index.cgi?action=display&board=exocet&thread=3280&page=1#27362#ixzz2BeiD9ZQn