So, with a cleaned up clutch master cylinder and the new slave / flexible pipe fitted, I put a little brake fluid in the reservoir and left it to fill the master cylinder for about 20 mins. Mug of tea done, I noticed the level had dropped however, it was leaking from the bottom of the reservoir rather than finding its way into the cylinder….!
On loosening up the clips and removing the reservoir, it was obvious that the stub pipe fitting in the bottom had come away so a soldering job was required. I once again, cleaned the reservoir and the stub pipe in the ultrasound bath and using some liquid flux, proceeded to heat up the container with a blowlamp and soldered up the connection again. Back on the car, all appears good with the reservoir underside staying dry overnight.
In the meantime, I checked the reverse lamp switch operation – one blown lamp and that was changed but circuit working correctly. I also checked the non-working cigarette lighter – power found to the socket but not operating when I tried the sat-nav… More playing required there – a new lighter fitting perhaps?
Next, the angle drive for the speedo cable. It was loose and leaking a little oil so I removed it again and perhaps I lost the spacer washer when switching the o/d over to the new box however, I put a 1mm thick Dowty seal in there that seems to have the correct dimension to allow the angle drive to tighten up and perhaps be a good seal too – time will tell….
Next job, the exhaust manifold. I noticed on removing it from the car that there was some miss-match with the porting. The gasket is almost a perfect fit around the head ports however, as can be seen in the photo, the manifold needed a bit of ‘massage’ to match more correctly the head. with a file and a Dremel, I managed to get a pretty good match – not sure if the extra flow will be noticeable in running but at least it’s more correct now.
Finally, clutch bleeding time. With Mrs Lewis’s petite size 38 at the ready, we set to. All the air seems to have bled out of the cylinder – the pipe ran clear – however, on pressing the piston back into the cylinder, there was still air in the system. With more bleeding, I finally reached a truly massive 6mm travel on the piston – enough to move the arm but not nearly enough. I think I’ll bleed again with the cylinder hanging vertically to let the air rise and make it easier to clear. I’d like to have best possible chance at getting it correct before starting up. The pedal feels lighter than previous – perhaps that’s a sign of more air in the system as well…. From another forum, it looks like 16mm is the required travel on the piston to operate correctly so there’s a fair way to go….!
The modified fuel pipe is ready to go onto the metering unit now and with the sensor in place, I’ll have a read-out of the pressure on the dash. That went together nicely and I just need to drill a chassis member now to put a securing clip around it to keep it tight.
Last push today – an outing along the coast into Wine-Country beckons tomorrow. Final checks and test with fuel pump on for leaks – all tight, no leaks.
I bled out the clutch again, hanging the slave cylinder vertically and that did the job. A good travel was found with a firm pedal.
The new centre section of the exhaust arrived on Friday so that went in however, not without a little massage… I had to cut approx 30mm off the length of the extractor outlet pipe to allow the rest of the system to fit together. I used some red RTV in the joints to seal them up.
A 90% reassembly of the interior next with just the gearlever surround panel left off in case I had to drop the box again…! It’s quite a delicate panel so better safe than sorry…
The engine ran almost first flick of the key after running the fuel pump for about 10 secs first. All injectors fired up and there was a smooth uptake on the clutch in 1st and reverse at least. And, it was quiet at idle with no bearing noise!
I checked the air flow through each throttle body and found they needed adjusting to balance them up after being removed and realigned best poss using a view through the open butterfly against the head port. Easy done with the linkage fitted last year.
After a clean up, I set out on a quick test drive around the valley Saturday evening and managed to get about 500m before losing drive…
With oil under the car, it seems there was a problem with the slave cylinder. A tow back with the Mrs at the wheel of the old diesel estate and I left the car till the next morning and cancelled the trip to the vineyard. At 11 p.m., I’d had enough for the day! Beer called; time for a green tea….
Under the car again and it became obvious that the slave cylinder was the culprit:
Somewhat annoying, over-extension in the cylinder had jammed the clutch disengaged so no drive. One securing bolt removed in this photo – not one missing…!!
I released the bracket after removing the cylinder and checked the cylinder bore / seal. All OK fortunately and with the cylinder mounted the other side of the bracket, I then had to bleed the system again.
With the Mrs away for a few days, I tried just leaving the cylinder hanging vertically and having a mug of tea. This actually seemed to do the trick with air bleeding out of the nipple a few times before just oil appeared and with the piston pushed fully in and a cable tie around the end of the cylinder to catch the piston, I proceeded to pump the pedal to get a good position for the actuator rod length before re-securing.
Full operation of the clutch resumed, piston safely half-way down the cylinder and a test drive on the cards. I raised the back of the car on axle stands just to check all was well with the clutch before heading out and that was it – all good.
Finally, a couple of hours later, back home, happy and satisfied the car will be set for a summer season with the rest of the group here. Fuel pressure ranged from 101-104 psi during the trip out, water temp remained at halfway and oil pressure was between 80psi and 30 when on the motorway / idle in town.
I did hear, with the back end raised, signs of a noisy offside rear hub bearing – next project I guess, after a break and bit of use!