Well, its been a bit busy doing my paid job, so not much time to work on the car.
I took the car up for its inspection, and unfortunately it didnt pass, but at least what they failed it on was all pretty minor, so I can head up there next week, with these things fixed, so it should be pretty straight forward next time around.
There was a brake fluid leak from where I hadnt tightened up one of the hoses quite enough...annoying, it only showed up as that had been the furthest I had driven the car since changing the hoses.
Also there were " oil leaks " which is bullshit, as I fixed them! but I didnt clean the outside of the oil pan all that well, so all I needed to do was give it a thorough degrease...I was hoping to get away with not doing this.....oh well should have known better.
Unfortunately after the degrease I found a minor leak in the gearbox from around the speedometer gear. Ok so I didnt notice that before, and the inspectors may have been partly right.
However why would there be oil leaking from around the speedo gear! the oil level in the gearbox should be below the level of this seal....unless the clown that owned it before me overfilled it...
I'll check the oil level next week, but here is a pic of the leak...which was worse when hot....which indicates its probably over filled.
I ended up fitting my brakes that were left over from the 5 stud hub project on my other car.
(pic from other car before removal)
My disc rotors and pads were all near new, all I needed to do was fix the right front wheel bearing....but I had a brain explosion and bent the knuckle trying to press out the hub...so I had to visit the junkyard to get another one.
Apart from some non standard wiring, for driving lights (which were not there) which I have removed..I hate that stuff.
There was a problem with the radiator cooling fan, it was running all the time.
Not only that it was going around backwards, trying to blow air through the radiator and out through the grille..epic fail.
I found that someone had just found any old wire with 12v on it, and connected it to the fan...but why would they do that ?
I disconnected the temporary wiring and reconnected the fan back to the factory harness plug.
In the GC, if the factory sensor fails, the fan would run all the time, its like a sort of fail safe...
In the diesel version the sensor is in the bottom of the radiator:
I didnt want to wait for the car to warm up to test it, so I disconnected the sensor, the fan should have come on....it didnt.
So I thought I'd check the power on the fan relay...I traced the plug, and there was nothing on the end....this would be a good reason why it didnt work!
I reached into the box of mazda relays, pulled from various cars that I stripped over the years, and found one that was the right type, SPDT, and right type of plug.
Just as well I checked the pinout of the plug, as it was totally different
I thought may be I would try and get the correct part, but I was feeling a little bit impatient, so I popped all the connectors out of the tab housing and clipped them into the spots to match the relay and plugged it in :
The problem with doing this is that now the wiring harness is non standard, I'll put a note in my book about this....but its this sort of thing that would annoy the next owner of this car! maybe I will change it back in the future.
While I was at it I repaired a headlamp wire which was joined by the twist and tape method....this was where an aftermarket driving light relay had been connected.
What else is wrong......when I was driving the car to have it inspected I noticed that there was a "hot dust" smell coming from under the dash.....you know the sort of smell the heater core makes when It gets hot for the first time in a few months.....
I thought I'd turn on the interior fan to see if the heater was hot.....and nothing...no air no noise...so it looks like the interior fan does not work for some reason.
Technically this car could be failed on roadworthy for this, as a working demister is a requirement....hardly anyone ever checks it so I'll keep it under my hat for now, but I might look at it next week before it goes in for its second inspection time permitting.
Should be a straight forward fix, I have all the parts anyway, I suspect it'll be either a tripped circuit breaker (yes its a circuit breaker not a fuse on the interior fan) or a burned out resistor pack. On non a/c cars like this one, there is an extra resistor in series with the motor to compensate for the fact that there is no evaporator core restricting the air flow.
I was curious though as to why the smell of hot heater core when it should be cold...in a GC there is a valve that controls the flow that connects to the heater control. I decided to have a look under the dash.
you almost have to be a contortionist to get under there for a look.
The arrow points to a repair....its really hard to see in the pic, but it looks like the pipe flange which is plastic, must have broken off at one stage, and has been glued back on.
This explains the coolant stains on the carpet...however I not sure I am satisfied with the repair...so I will replace it..
The reason that its hot while turned off looks to be due to the valve not closing properly, so I would need to replace it anyway.
Why would it break off like that ? I wonder if the vibrattion from the diesel engine (yes its noticeably more than a non diesel) causes a fatigue crack in the plastic over time...
I thought maybe it had been replaced with an after market core without a valve (like this) :
FORD AR - AS TELSTAR HEATER CORE - CAR HEATER - HEATER - eBay Other, Air Conditioning, Heating, Car Parts, Accessories, Cars, Bikes, Boats. (end time 17-May-10 14:44:09 AEST)
Which while being made of metal and will likely last forever, has no control valve, and would need an external tap control, which while being not impossible, is a bit of a pain and would result in a heater thats either on or off with no in between!....plus $370 is a bit steep considering I can get one from rock auto for half that shipped (but it is only plastic/alum, but has the factory valve!)
I have a used spare anyway thats in good cond, I might add a pig tail loop into the heater hose so as to help damp out any vibrations.
More to come.
Looks like the LPG injection project will now go on hold until at least late July thanks to work commitments