A new project that definitely isn't beige

[steve_earwig]

Ah, splendid Is that with new BSI or did you manage to dry the old one out?

Flashing headlamp kind of rings a bell but I can't remember what

[steve_earwig]

viewtopic.php?f=3&t=8565&p=82686&hilit= ... ght#p82686

[jonsowman]

Replacement BSI. I decided that I wouldn't ever really trust the damaged one, and wouldn't be sure that other faults were/weren't caused by it. Managed to clone the old one to a replacement from Ade, so didn't have to swap the engine ECU/keys/transponders, and the mileage didn't change. I'll do a how-to on this in the next couple of days.

The ABS/ESP warning has gone away after recalibrating the steering wheel angle sensor

PP2k says the light switch stalk is the problem. Confirmed because if I try to twist the switch further towards me than it wants to go, the lights go off and the warning lamp stops flashing. So seems like it's the contacts in the COMM2000 unit, so I'll have to have this off to see if I can't clean them up

[steve_earwig]

That sounds bloody good, yes please on the how to

Start by explaining how you can clone a waterlogged and presumably completely dead BSI!

[gumby6371]

Nicely done Jon!
I hate to spoil the mood but it does however appear to be coming together far too quickly for any project car I've ever heard of!!!!
You haven't had anywhere near enough time to have the other half bend your ear about it sitting on the drive...blah...blah...blah

What are you going to buy next week???

[jonsowman]

I'll get the how-to done ASAP, need to collect and edit some pictures. Fair warning: involves butchering the BSI casing!

Nicely done Jon!
I hate to spoil the mood but it does however appear to be coming together far too quickly for any project car I've ever heard of!!!!

Don't worry, plenty more to do on it yet. Need to replace heater matrix seal, stat and temp sensor then flush & refill the coolant. Not to mention replacing all the interior trim

[gumby6371]

Should keep you busy for a while then!
BTW is my spare com unit any good to you?

[jonsowman]

That sounds bloody good, yes please on the how to

Start by explaining how you can clone a waterlogged and presumably completely dead BSI!

As promised: viewtopic.php?f=3&t=23317

Should keep you busy for a while then!
BTW is my spare com unit any good to you?

I need to take mine off and see what state it's in. If you're wanting to shift it imminently, let me know. Otherwise I should be able to let you know in the next few days once I have some time to pull mine apart

[Welly]

Doff's one's Hat in your general direction Sir

[Doggy]

Good progress there Jon, keep up the good work.

[jonsowman]

A brief update:

Dismantled the COM 2000 to see about the light switch fault and reattach the trip computer button. The latter went fine, but the light switch contacts are exposed pads on FFC cable, and it's totally worn through. Quite apart from the fact that it's a total **** to reassemble properly without 8 hands! So new one going to be ordered I think.

The wipers don't work. I thought this was the COM 2000 originally, but it turns out no. Using the Actuator Test in PP2k doesn't work either. Pretty sure this is the wiper motor, since applying 12V direct to the motor still won't move it. Both 'fast' and 'slow' connections appear to be open circuit. So a new wiper motor going to be required as well.

Lastly, the window mirror switch has also worn through its PCB track connectors. It's in a terrible state, not reparable. So another spare part to order.

Annoying when stuff has to be replaced rather than me being able to fix it, but there we go.

I've got the sealing rings for the heater matrix joint. Does anyone have any opinions on whether to apply silicone sealant to the union as well? Is this likely to make the seal better or worse?

[Welly]

I'm not sure how the pipework joins to the HM but if the pipework joints rely on O-rings to seal then that is what must be used and maybe with a dab of lubricant to ease the assembly. If you introduce another sealant you might upset the seating of the O-rings and then you won't know whether the O-rings are making the seal or the mastic.

[jonsowman]

Another update, containing good and bad news!

Good news: heater matrix seals and degassing tank replaced. No leaks from either now.

Bad news: I think there were actually 2 leaks in the cabin The seals were one, but there is some coolant coming from the heater matrix housing when left overnight. Interestingly, this doesn't leak when the engine is running, even when up to temperature. The gap the coolant comes from is the one between the matrix plastic and the housing (see pic).

So it looks like I'm going to have to replace the matrix as well. What a faff!

In happier news, I flushed the radiator and matrix when changing the coolant. No sign of bubbles in the header tank, and no pressurising of coolant hoses. Rad warms up evenly all over. Rad hoses stay cold until ~85C on the gauge, when the 'stat opens. So this points towards the head gasket being good, and the rest of the coolant system being intact.

[Welly]

Something must shrink when cooling down and allow some seepage, maybe a small crack or something. What a faff indeed, good news on the rest of the cooling system though.

[Doggy]

Good news indeed. I would be tempted to bypass the matrix and get some miles on it to be doubly sure.