Front bumper Assembly of the front bumper is rather straightforward: two front studs and two bolts on either side provide a robust mount. Rear bumper See also mount modification and bumper seal. Apart from getting the nuts and bolts into position given the limited space between the bumper and chassis,......
Continue reading...assemble
No draught ventilator restoration (front)
See also prior posts about ventilator deconstruction and glass setting tape. As discussed in the ventilator glass assembly post, the bolt that passes through the glass pane acts as an axle for the twist handle lever that holds the window shut. Glass setting tape on one side and a rubber......
Continue reading...Alpine DIN installation
The Alpine double-DIN head unit has several related components, including: microphone for hands-free operation stereo speakers backup (rear) camera radio antenna wiring connection to the reverse switch (triggers backup camera) wiring connection to the handbrake switch (safety precaution) A CLD swatch was rolled on to the back of the speaker......
Continue reading...Exhaust system installation
See also exhaust system planning post. Our plan to install a new model-correct single exhaust for the 2.4 engine was theoretically straightforward, but ran into the hard reality of nut-and-bolt installation and fitment. Like so many aftermarket products, the new stainless steel exhaust was almost to specification, but not quite.......
Continue reading...Fuel system boot connections
Installation of the petrol tank allows us to complete the fuel system connections in the boot. The fuel level sending unit is connected by three wires: a black ground that fastens to one of the unit bolts; an orange wire attaches to the “W” terminal for the fuel warning light;......
Continue reading...Gearbox selector ring and grommet
The gearbox selector (shifter) protrudes through the tunnel gearbox cover, and is finished by a rubber grommet and ring (which screws into the fiberglass tunnel cover and holds the grommet in place). Four small holes were punched in the grommet; the ring was sanded and then spray painted with faux......
Continue reading...Carburetors and air intake
The twin Solex carburetors mount on top of the intake manifold, and there are a number of fuel, choke, and accelerator connections....
Continue reading...Engine fixings
Now that the engine and gearbox/overdrive assembly is mounted securely on the chassis, a number subcomponents and connections can be permanently installed. Engine heater hoses Two hoses at the rear of the engine connect with the heater pipes. Starter main feed The main wire from the starter motor terminates at......
Continue reading...Engine install
Without the front suspension, installing the engine from under the chassis is a safe and relatively anxiety-free method with a four-post lift. First, the alternator and oil filter are removed; the intake and exhaust manifolds were not yet attached. Next, the engine/gearbox is moved with an engine hoist to marks......
Continue reading...Starter motor install and engine fittings
STARTER MOTOR Given the new aluminum flywheel, larger 3.8 clutch, and longer slave clutch cylinder, the domino effect continues with the addition of a new Denso starter motor. Each time a new component is added, the issue of precise fit arises, and the starter motor wasn’t without its share of......
Continue reading...
