For some, like me, there's no known cure. - Page 3 - MG-Rover.org Forums
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post #41 of 50 (permalink) Old 11-03-2017, 19:18 Thread Starter
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Location: Gloucestershire - Cotswold Cockney
Car: MG Montego Turbo; 620ti x3; MG ZS; MGF and MG ZT 1.8t x2; MG ZT-T x1
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More progress.

More progress today. Fitted new Timing Belt and used a CRANKshaft Pulley I had painted using some old dregs in the bottom of a couple of Tins of Hammerite. In fact I made a small batch few years ago and this is the last of that batch. Locating that little slot in the circumference of the Crankshaft Pulley is always difficult. Painting the Pulley in this way means the "Safe" engine position can be located and set at a glance. No more groping about in the dark for that little slot. :~



Also, very time consuming accessing this little 8mm Timing Belt Cover Bolt located deep behind the Power Steering Pump Drive Belt Tensioner which needs to be partially undone and move aside.. :~



I attach a series of other images that I took during the work.

Apparently ... in a parallel universe MGJohn drives .........A.......

B>>M>>W ....

Arrrrrggghhhhh......... ......
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post #42 of 50 (permalink) Old 15-03-2017, 18:25 Thread Starter
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Thumbs up Fired up for the first time today.

Took advantage of the better weather conditions over the past two days and made good progress. Today saw beautiful cloudless blue skies and continuous warm sunshine. So in between the races at the nearby Cheltenham Racing Festival on TV, finally got it 99% back together and ready for that first post-repair start up. Here are the various checks and adjustments whilst fitting the new timing belt. The most important check being turning the engine over manually to ensure no metal to metal contact. Easier to do that with Spark Plugs removed to avoid struggling against compression. Here is a series of images showing some of the fitting and checking work :~



Belt after several manual rotations of the engine :~



Setting the Timing Belt Tensioner ~ will check it again after a few miles use as it usually moves with use. :~



My "Third Hand" holding the Polyvee Auxiliary Drive belt Tensioner clear to enable the Belt to fit over all the Pulleys. :~



View of the "Third Hand" from above showing ample slack in the Belt enabling it to slip over the Alternator Pulley. The Spring in those tensioners are very strong... :~



Then comes the "acid test" :~

View My Video

It lives again! ...

My camera has picked up those engine noises massively. Actually, to my naked ears, the engine settled down later to a nice pleasant rustle from the Valve Gear.... not a trace of "Tappet" noise. Looks like the Diesel Fuel Lubricant has acted quickly.

Apparently ... in a parallel universe MGJohn drives .........A.......

B>>M>>W ....

Arrrrrggghhhhh......... ......
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post #43 of 50 (permalink) Old 19-03-2017, 22:22 Thread Starter
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Join Date: Jul 2003
Location: Gloucestershire - Cotswold Cockney
Car: MG Montego Turbo; 620ti x3; MG ZS; MGF and MG ZT 1.8t x2; MG ZT-T x1
Posts: 21,204
A Start ~ Stop Day today.

Despite finding several more minor bodges which needed sorting prior to putting the wheel back on and getting the car off the Axle Stands, I was able to take the car for a gentle six mile run to get the Diesel Fuel Lubricant to do its work cleansing any old oil sludge remaining from previous ownership.

I was delighted with how the car ran and in the event, those six miles extended to ten including an eventful stop to put a few Gallons of Shell's 99 Ron to freshen up the few gallons of fuel in the tank which is at least six months old. I parked up the car near a local beauty spot and took a couple of images :~





The event? After filling with fresh fuel, the engine would not start. Nothing although the instruments lit up as usual. No clicks or .. anything. Suspecting the old battery had expired, I phoned my son and asked him to bring out a couple of good spare batteries and some jumper leads. Still dead and so we pushed it to one side at the Shell Petrol Station after telling the staff we have a dead car and will be back to take it away.

We returned in my trusty 620ti with fast fit tow shaft I made up years ago. Soon had the car towed off the Petrol Station with my younger son steering the car. I had mentioned I would pull up on a safe quiet road and swap drivers. He would tow me up to 10-15mph and I would drop the clutch in 2nd gear with ignition on. Immediate fire up. So with disassembled the Tow Shaft set up and drive both cars home.

Dark now so I allowed the engine to cool for about and hour then placed a large bowl under the Sump. Removed the 15mm Sump Plug. The Diesel Fuel quickly drained but I'll leave it for several hours so that most of the stuff will trickle out. Then in will go some good quality ( GM ) 10-40 Semi-synthetic. This little Work Light was great help in the dark.



Earlier, one of the previous ownership bodges was a taped up Front Brake Pad Sensor. I carefully undid the Cable Tie and the Electrical Tape intending to fit it whilst the Wheel was removed. Then I saw why it had been taped up. The very fine connector wire had been broken and taped up out of the way. I'll buy and fit a new one. They are not very expensive. Bit of a pain to fit though.



Whilst reassembling the various connections and Wheel Arch Fittings in their correct locations, I spotted another Connector Taped up. This was loose and above the PAS Pump Assembly. No idea where it's meant to be connected. Is there a low PAS Fluid Level Sensor? Up against the clock now so not much time to solve that little loose end mystery. Here's that loose end... :~



Tomorrow if time allows, I will check the Starter Motor, its Solenoid and various Electrical Connections including Earths. If that draws a blank, I'll remove the Starter from a SORN Car and fit that. I'll also check and test the original Starter when off the car. Shame about the non-starter. Doing so well with progress up to that point and already thinking about the several cosmetic issues that need my attention. Nothing serious but, as usual all time consuming. These thing are sent to try us according to some.

Oh well. Tomorrow is another day ... as they also say ... .....

Apparently ... in a parallel universe MGJohn drives .........A.......

B>>M>>W ....

Arrrrrggghhhhh......... ......
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post #44 of 50 (permalink) Old 20-03-2017, 00:10 Thread Starter
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There's more to report on Sunday's activities.

Four months exposure to the winter weather had a detrimental effect on the Front Brake Disc. Light corrosion and a patch showing the outline of the Pad. Disc was partially seized until using a stout Screwdriver in the Ventilation web, I was abled to manually break that grip of seizure.

Then using a worn File and worn Wire Brush, with the car in 1st Gear and engine at idle, a couple of minutes had the Disc looking much better. A few Brake applications when driving should improve it further. This is how I worked. If you try this, do PLEASE think about what you are doing. It can be dangerous if you drop your guard briefly. Exercise great care. You do not want to have a ten hour wait at your local A&E... For those reasons and others, I am NOT recommending this process. You have been warned.

Engine at idle in 1st gear


By the way, after a few rotations, all the doors locked. Two of my cars have this security facility which has its uses. However, if you only have ONE Key, you will lock yourself out if your 75/ZT has this security facility activated. So another warning. If you only have ONE key, lower the driver's window. Fortunately I do have a second key so no harm done. Must remember that. One of my cars has only one active key but I had a blank empty Key cut as a safeguard for that car pending getting another active Key set up.

Apparently ... in a parallel universe MGJohn drives .........A.......

B>>M>>W ....

Arrrrrggghhhhh......... ......
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post #45 of 50 (permalink) Old 20-03-2017, 17:25 Thread Starter
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Good day Sunshine... Immediate Start

Continuous heavy rain until early afternoon. Then fine Sunshine. Lifted the bonnet and in the superb light, looked behind and below the Inlet Manifold at the Starter Motor. One of the Solenoid Spade Connectors had become detached. That's why the car's engine wouldn't start! Reattached it and turned the Key. Engine burst into life.

Moral, ALWAYS check the simple things first, even in the dark! Convinced it was faulty, I was all prepared to remove the good starter from an SORN car. In the event, a few seconds to check and fix...



That drained Diesel Fuel from the sump overnight had done its job. It came out very black even after only ten miles of light running. Tipped it into the now empty GM ( Bought from local Vauxhall Dealership ) 10-40 Semi-Synthetic Engine Oil plastic bottle after filling the engine with the new oil. Will take old to the local Council Waste facility along with some other old engine oil in other plastic bottles. These images illustrate what is left in the engine after a routine engine oil change.





I want that remnant sludge out of my engines. It makes a BIG difference as I soon found when I drove the car later today. Nice near silent rustle from the Valve Gear at Idle ... no clacketty-clack Diesel Type noises from varnish sticking Cam Followers.

Then with all the tools cleared away, drove the car to a nearby garage and checked and adjusted the Tyre Pressures. One was showing only 18psi .. not bad since I last checked them months ago. Then drove home the long way ... adding about ten miles to the trip. As I left the Filling Station after the tyre check, a sleek Mercedes pulled up alongside at the Traffic Lights. Merc driver edging forward ready for the Traffic Lights change from Red..... Oh yeah. Now very confident in the car thought I would participate. The Merc driver was a millisecond or two quicker off the mark than my ZT-T. I held onto near the red line in first, second and part of third mainly alongside the Merc when my car edged in front and then the Merc dropped back quickly. This engine is good... . Better, far better than I expected. Back home I checked the Top Coolant Hoses for excess pressure and an hour later, undid the Coolant Expansion Bottle Cap. Just the barest trace of a "Shuush" sound as the little remaining Cooling System Pressure was released. Good sign that with a still warm engine and the coolant level was where it should be.

Delighted with the way this car is shaping up now. I got some SPEEDFLush ready to put into the cooling system. Then I remembered I had fitted an Elastomer Cylinder Head Gasket to this engine and that aggressive Cooling System Flush may be too aggressive for the Elastomer Seals. .. about that but, will not risk it. I will use one Dishwasher Tablet in the water only currently in the system then drain and flush. Then fit 50-50 "Blue" Antifreeze mix. I like my engines and their cooling systems to be very clean in their unseen insides.

Then the car will be my daily driver for a few weeks whilst I watch it like a Hawk.

There's one mechanical job remaining. When the nearside wheel arch liner dropped out and went under the front wheel, it tore out the ABS Sensor Cable. I have a new replacement but, reading some of the ABS fitting stuff on this and others sites it's not a task I look forward too.

Apparently ... in a parallel universe MGJohn drives .........A.......

B>>M>>W ....

Arrrrrggghhhhh......... ......
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post #46 of 50 (permalink) Old 20-03-2017, 21:34
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There's one mechanical job remaining. When the nearside wheel arch liner dropped out and went under the front wheel, it tore out the ABS Sensor Cable. I have a new replacement but, reading some of the ABS fitting stuff on this and others sites it's not a task I look forward too.
From similar experience on our 25, I`d take the fresh hub route. Some on ebay from 40.
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post #47 of 50 (permalink) Old 21-03-2017, 21:40 Thread Starter
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Thumbs up Been considering doing that.

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Originally Posted by deebee View Post
From similar experience on our 25, I`d take the fresh hub route. Some on ebay from 40.
Yes, had that in mind since searching for clues when it first happened. Any links handy for the 40 item? I will search anyway. I still plan to try removing the old Sensor first on the car and if that proves difficult, then a hub could be a possible long stop back up.

Apparently ... in a parallel universe MGJohn drives .........A.......

B>>M>>W ....

Arrrrrggghhhhh......... ......

Last edited by MGJohn; 21-03-2017 at 22:04.
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post #48 of 50 (permalink) Old 21-03-2017, 21:56 Thread Starter
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More loose ends and details sorted today. Plus a loose mystery Connector.

Spent an hour on the car today in between brief periods of heavy Hailstone downpours. Yes, soaked again ...

I refitted the Top Timing Belt Cover after checking the Belt tensioner Adjustment was still as it should be. Looked OK.



Then on with the upper Timing Belt Cover :~



Added one Dishwasher Tablet to the Water ( only water at the moment ) in the cooling system :~



Finally, here's a loose end yet to be tied. This loose Connector above the PAS Pump Location in the 1.8t I discovered when finalising things in that area a couple of days ago. No obvious things nearby which it may be connected to. Any ideas what its for? I do know that on many cars there will always be some unused connections on the Electrical Loom for extras on higher specification cars. Any thoughts?



Then took a small parcel to the Post Office in the car. Guess what... on the way back the Engine Check Light became illuminated... typical ... ... back to the drawing board. ...

Apparently ... in a parallel universe MGJohn drives .........A.......

B>>M>>W ....

Arrrrrggghhhhh......... ......

Last edited by MGJohn; 21-03-2017 at 22:02.
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post #49 of 50 (permalink) Old 22-03-2017, 10:59
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Yes, had that in mind since searching for clues when it first happened. Any links handy for the 40 item? I will search anyway. I still plan to try removing the old Sensor first on the car and if that proves difficult, then a hub could be a possible long stop back up.
PM with links sent
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post #50 of 50 (permalink) Old 22-03-2017, 12:30 Thread Starter
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Originally Posted by deebee View Post
PM with links sent
Thank you. Reply sent.

Apparently ... in a parallel universe MGJohn drives .........A.......

B>>M>>W ....

Arrrrrggghhhhh......... ......
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