Sign in to follow this  
Followers 0
MikeT

My 404 Coupé Injection

176 posts in this topic

Headliner trim installed at the front, along with the sunvisors.

IMG_5905.jpg

1 person likes this

Share this post


Link to post
Share on other sites

Wiper switch wired up and dashboard pad added.  New Peugeot NOS upper heater hose added.

 

IMG-5909.jpg
IMG-5908.jpg

1 person likes this

Share this post


Link to post
Share on other sites

Not a lot was done recently.  I got a couple of snaps fitted to the transmission tunnel carpet, which was a test as much as anything else, but it worked.  Then I found that the spacers for the carpet snaps were mostly missing.  The snaps are screwed into the floor but have spacers to allow for the extra thickness of the carpeting underlay and insulation.  So I bought some bronze spacers and have to grind them to size and they will become fit for purpose.

 

Also, all 18 Kugelfischer DL020B and DL020D fuel injectors I have for the engine (of course it needs only four at any given time) have been tested and matched into pressure classes by Nottingham Diesel Services Ltd. and DHL should have them back in my hands shortly.  I'll post photos when they're here.

1 person likes this

Share this post


Link to post
Share on other sites

Injectors-tested.jpg

 

Today I got my 18 cleaned and tested injectors back from Nottingham Diesel Services Ltd.

 

The 6 NOS:
2 x DL0 20D - release at 37 bar, good jet, no drips
3 x DL0 20D - release at 35 bar, good jet, no drips
1 x DL0 20B - release at 33 bar, good jet, no drips

 

The 4 originals from my car's engine:
1 x DL0 20B - release at 29 bar, good jet, no drips
3 x DL0 20B - release at 27 bar, good jet, no drips

 

Random spare injectors:
3 x DL0 20B - release at 30-32 bar, good jet, small drip but OK
3 x DL0 20B - release at 22-25 bar, jet OK, but drips under residual pressure that could make cold and warm starting a problem.
2 x DL0 20B - defective

 

I'm going to use 4 x NOS injectors (DL0 20D).

1 person likes this

Share this post


Link to post
Share on other sites

R-Window-trim-mounted.jpg

As you may recall, before Christmas I put the rear window in but there were a couple of issues: the lower stainless steel trim piece was perfectly straight and the class is slightly curved, so it was constantly trying to pop the clips out.  And so it did, once the glass was in.

 

After pulling the trim off I realized that the problem was also that the replica clips were about 2mm shorter than the originals and so didn't penetrate far enough inside the seal's rubber slot to engage with the small channel at the end where the hooked bit goes.  So each of the 30 clips had to be adjusted carefully by hand to match the depth of the 16 remaining originals, which were cadmium plated a couple of years ago.  In doing this - they're made of spring steel - 5 of the 30 snapped but 25 survived. 

 

I then mounted them to the SS trim along with the 16 originals and so far it's holding well enough.  Actually the rubber seal relies upon the window aperture to keep it tight.  So during installation I'm going to have to ensure the helpers push hard on each clip as I pull the rubber seal through to the inside of the car to make sure the seal clamps the clip in the right position (fully inserted).

Share this post


Link to post
Share on other sites

Today, with the able help of my two daughters I remounted the rear window of the 404 Coupé with no problem at all, and the modified clips are working perfectly.

 

Took 5 minutes to install and this time I started from the bottom of the seal and finished at the top.  I used a smaller gauge nylon cord to do the lip service (!) this time and it worked beautifully.

 

YES!!

 

Rear-window-mounted.jpg

1 person likes this

Share this post


Link to post
Share on other sites

Still working...from home.  Waiting for the golden handshake that will never come:lol:

 

Rear parcel shelf and leather rear bench installed.  For the moment there will be no speakers, because my 1981 Blaupunkts are dead.

Rear-Seat-installed.jpg

1 person likes this

Share this post


Link to post
Share on other sites

And today, the naughty....err....dirty bits....

Removal of crankshaft, camshaft, pistons, liners...

Summary: 

- Crankshaft journals looks more or less OK: 0.3 mm should do.
- The upper (compression, I presume) rings were broken on all 4 pistons (!!)
- Lifters and peak of the cams on cylinder 4 were heavily worn (oddly, the other were OK)
- Sleeves were not too rusty in the water jacket area and the block where the seals mate is perfect.
- There was a lot of very thick sediment deposited in the lower sides of cylinders 1 and 2, especially by the block drain hole on #1.

I have new pistons, sleeves etc; however I could use a new cam or maybe get a regrind.  Need new lifters of course.

Old-Pistons-and-broken-rings.jpgOld-Cam-and-lifter.jpgOld-Liners.jpgempty-block-2.jpgEmpty-block.jpg

1 person likes this

Share this post


Link to post
Share on other sites
The engine is totally apart now, as noted.  The cam has bad wear so I am trying to source a new one from Le Club 404's stock.  The new head and piston/sleeve kit are in the two cardboard boxes.
Engine-disassembled.jpg
 
Today, after cleaning off the engine block and moving it to where you see it above, I made 10 spacers for the carpet snaps.  These space the carpet appropriately for the thickness of the undelay, so they're not puckered.
Carpet-Passenger-Floor.jpg
 
Original Peugeot clips used for the visible ones. The rest are virtually the same. 
Carpet-Clip-1.jpg
1 person likes this

Share this post


Link to post
Share on other sites

The underlay for the rear transmission tunnel was installed along with the carpet, the rear floor carpets.... and then the passenger seat.
Passenger-seat.jpg

 

My wife Sandy tried out the seat for height and comfort.
Sandy-in-passenger-seat.jpg

1 person likes this

Share this post


Link to post
Share on other sites

Drilled 3 holes in the panels to mount the new carpet in the front driver's side.  The fourth hole was already there above the accelerator pedal.  

Driver-s-side-carpet.jpg

 

Also mounted the new speedometer cable and the accelerator cable.  The driver's seat was a bit of a bear to install because the captive bolts in the bodyshell were not long enough to penetrate the new (thicker) seat runners and so I had to knock it out and put a bolt and (blind) nut inside one.  

Driver-s-seat-in.jpg

 

The interior is now done apart from the transmission tunnel, which is still naked because I have to install the C3 gearbox and its Nardi floor shifter before final trimming. That'll be a while then.

Interior-done.jpg

1 person likes this

Share this post


Link to post
Share on other sites

Mounted the glovebox on Saturday.

Glovebox.jpg

 

Sunday I cleaned and sorted all my nuts and bolts into the proper sizes.

1 person likes this

Share this post


Link to post
Share on other sites

Saturday I'm going to rebuild the AEG/KF fuel lift pump with a kit supplied by my buddy Peter van Deukeren from the Netherlands.

The tiny bearings:


AEG-Pump-bearings.jpg

 

The shaft seal:
Seal-for-AEG-pump.jpg

 

The kit:
Peter-s-AEG-rebuild-kit.jpg

 

My two AEG PLF 5 pumps:
AEG-fuel-pumps.jpg


And today, because I couldn't find the original clips for the dash pad, I made these out of 1mm thick spare rocker panel/sill material. They now have to be covered with a thin layer of black vinyl. They join the top of the soft dashboard pad with the soft A-pillar trims. Each one has been shaped by hand to fit each side very well.

Dash-clip-replicas.jpg

1 person likes this

Share this post


Link to post
Share on other sites

Dashboard clips covered with vinyl.

dash-clips-covered.jpg

Passenger side:
passenger-side-dash-clip.jpg

Driver's side.
Driver-s-side-dash-clip.jpg

It was a pretty decent effort, I am pleased with the result.

1 person likes this

Share this post


Link to post
Share on other sites

Dismantling of the AEG/KF fuel lift pump.

A little bit of electrical tape over the motor's drive pinion facilitated the armature's extraction from the pump body without in any way damaging the original grease seal, which is still supple.  So I will leave it in place and use the same technique to re-insert the pinion through this seal.
Grease-seal-AEG.jpg

The freed armature.
IMG-6262.jpg

Making up some different sized slotted washers in the garage made short work of extracting the tiny drive pinion and nearly as tiny bearings.
IMG-6265.jpg

Armature mounted on a drill in a vise so I could polish the commutator/slip ring with fine emery cloth.
IMG-6267.jpg

Comparison between the armature of my car (4598609) on the right and that of a scrapped Canadian Cabriolet (6800519) on the left. 4598609 has done 83,000 miles.  I bought the entire drivetrain from 6800519 in 1982, and at least the electric motor seems to show the traces of more like 200.000 miles...
IMG-6268.jpg

1 person likes this

Share this post


Link to post
Share on other sites

Today I pressed the new bearings onto the motor shaft with a vise and then the pinion gear after it was inserted into and through the grease seal in the underside of the motor mounting plate.  Checked the length of the original brushes: 6 mm and 9 mm....too short, so I looked in my spare parts stock and found two new or nearly new ones, both 12 mm long.  Then the motor was tested and it was SO smooth!

AEG-electrical-part-rebuilt-and-tested.j

Next task: the hydraulic part of the pump, which sits below the electrical part.

1 person likes this

Share this post


Link to post
Share on other sites

Today I reassembled the hydraulic part od the AEG/KF PLF5A fuel lift pump.

Bad surprise: despite the excellent condition of the electrical part of the original pump that equipped my car, the same could not be said of the hydraulic part.  The idler pinion inside the pump chamber was seized to its shaft!  The last time I ran the engine was about 2005 so the seizure occurred after that....I presume after I disassembled the car in 2016.  Also, the lower plate that covers the pump chamber has a regulation valve that is supposed to be removed and checked during a rebuild like this and it too was seized!  Anyway, all was not lost...

...because I have a spare lift pump from a car I used to own in 1981-1985 and its hydraulic portion was perfect.  All it needed was a thorough cleaning.
AEG-comparison.jpg

Cleaning nearly done and the last bits about to go back together....
AEG-hydraulic-open.jpg

And it's together.  I did another dry run test with it all assembled and it sounded good.  I should try a pump test, I suppose, though I have no reason to think it won't pump.
AEG-assembled.jpg

1 person likes this

Share this post


Link to post
Share on other sites

SEV-35-HS.jpg

 

I thought I'd treat the engine to a set of period spark plugs.  This set came from Italy, S.E.V. Marchal 35HS.

1 person likes this

Share this post


Link to post
Share on other sites

Last weekend I repainted the rearview mirror body and reassembled and mounted it.  Harry was giving me a hard time over not yet having done that!  Quite rightly!

Mirror-installed.jpg

 

Second time doing the driver's door panel.  The window winder was not happy staying in place and that was down to the padding under the vinyl being too thick next to the embellisher.  I also had to remount the lower part of the vinyl in order to slightly recontour the lower edge to better fit. And finally, the screws under the armrest were mounted.

Reglueing-driver-s-door-vinyl.jpgDriver-s-door-panel-remounted.jpg

I got new lifters and timing chain tensioner from Alveas in France, and two sets of NGK BP7ES from Rock Auto.

New-lifters-tensioner-plugs.jpg

1 person likes this

Share this post


Link to post
Share on other sites

Zsolt Parragh in Hungary kindly sent me this tiny commutator for the AEG-KF fuel lift pump of the 404C - for free!  Zsolt also has a 404C and his needed a new commutator, so he had a small batch made up.  Very generous of him.

 

new-commutator.jpg

1 person likes this

Share this post


Link to post
Share on other sites

404 C seatbelts in dark blue.  US-made.  Yes, lap only, as when it was new!

 

Seat-Belts.jpg

1 person likes this

Share this post


Link to post
Share on other sites
Seat belts mounted 
seat-belts-installed.jpg
 
High temperature paint on the brake shoes - rear linings need to be changed 
brake-shoes.jpg
 
Whipped the brush holder out of the the SEV-Motorola alternator - dirty inside
dirty-slip-ring-alt.jpg
 
Brush holder before cleaning
alt-brushes-holder.jpg
 
clean slip rings
cleaned-slip-ring-alt.jpg
 
Remounting. (the bolts holding the brush holder in are 1/8 inch, which is neither nor 5.5 mm.  American parts!
brushes-inserted-to-alt.jpg
1 person likes this

Share this post


Link to post
Share on other sites

Rear brakes mounted - handbrake connected and able to hold the car!  A good step forward.

LR-brake.jpg
RR-brake.jpg

Share this post


Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!


Register a new account

Sign in

Already have an account? Sign in here.


Sign In Now
Sign in to follow this  
Followers 0

    Chatbox
    You don't have permission to chat.
    Load More