Cosworth 2.9litre in my Crewwy

[toomanytoys]

I hope the linkage problem is sorted now... at least as a "2 monther....".....

[dickspanner]

Had a bit of a nightmare with the gearlinkage linkage to be honest. Ended up trying three different end shafts and none of them would stay socketed when selecting back gates of the gear selection process.

Started off with some 5mm plate and made the bracket that bolts to the gearbox. Bolted the bracket to the gearbox and encapsulated the nuts to it, so it was rock solid when bolted in position. Took the braket off the selector shaft and chopped off the part of the bracket which bolted to the gearbox. Assembled it all and the over a period of screaming obsenities at the two inanimate pieces of steel which could not stay where I wanted them to, I finally got it into a position that allowed the ball to stay in the cup over the full selection travel distance.

Then some awwww awwww f*@k F*@k welding, as the crewwy was only 24inches off the ground, and the only way I could weld it was to have the position of welding above my belly, I tack welded it into position. I sudden pange of pain, a reflex body curl upwards and now sore head it was fixed in position. Checked and it appeared to hit all gears. Quick look at belly and now a second smouldering belly button. Went back under and tacked it further, removed it and fully welded it up. All bolted together and hey presto 5 forward gears without a problem............. Saying that, there is a slight problem, No Reverse DUCK effin DUCK Duck. After falling to the ground like an exhaust man in the desert and crying for a while. Decided 'Thats it!!!!!! stupid chuffing effin thing.'

End result, mechanic is collecting it today to sort out the cooling, see if he can get reverse and then hopefully sending it in for an MOT.

Will keep people posted.

I did however, take it for a small drive last nigh. Saying a small drive I mean round and round in a few circles.

Dickspanner

[dickspanner]

Here is another question about the cooling. I had the engine running last night and after it running for several mins and the water temp gauge showing 105 the rad at the front was still cold to the touch. I pulled the top hose of and pushed a hose pipe in and water came out of bottom hose ok. So the circuit was full of water and water came out of the top bleed screw.

When I checked the hoses at front after dropping spare wheel holder they were still cool to touch. I did however notice that the electric fan on the rad appears to have two hose connections on it as though you link the heater circuit in and it acts as an electronic water pump.
Can anybody confirm that the electronic radiator fan has a water circuit built in? If so, where should this be connected to? I looked through my Haynes comic and it showed nothing. Sorry no pics to upload at present.

Is there any tips on bleeding the system out as I think there may be airlocks in the whole thing but do not know where to begin with the cosworth side of things or the VW side of things.

Cheers

dickspanner

[Pepperami]

I reversed (oops sorry sore point ) mine on to some ramps to get the rear as high as possible. Then went through the bleeding procedure. Run for a couple of minutes top up expansion tank run for a couple of minutes check rad full etc. Making sure the heater matrix is full. It may take a while but i haven't had to worry about it since.

[dickspanner]

I know what you are saying pep. I had a hose pipe on one of heater hoses and water flowed out of other side of it so I presumed it had water in, however I did do that task with the crewwy flat instead of inclined.

If my mechanic drops it back off tonight then I may jack the back end up into the air and try the same exercise again if he has not resolved the problem.

Will post up about it tonight. More interested in these two what appear to be hose connectors on the fan at the moment.

Dickspanner

[Pepperami]

My theory is if you get the expansion tank to be the highest point bubbles rise, rad and matrix fill. Worked for me when the Scooby was gobbing out water.

[toomanytoys]

The fans are multifit, the "hose" connections on the fan are for certain "VAG" cars that have a "fresh air" feed to the fan to cool it (eg, A100 5cyl turbo's)

If the feed to the rad isnt getting warm, then the coolant isnt circulating enough.. so either bleed and bleed and bleed it, stat ok/opening/no blockages.... or its the cozzy pump isnt man enough to pump the coolant the distance, so gonna need a "davis craig" electric pump I am afraid...

The "105c" was assumed to be correct?? not just a high reading... as there is a lot of water and it does take a while to heat up....

a good fast idle is needed when bleeding... 1500-2000 usually does it.. from cold... let it warm up to get a bit of pressure... bleed rad...

[dickspanner]

Spot on Si, so I had better no connect water to those pipes. LOL.

Going to try and bleed the system more, found a inline water pump at my local jag breaker that I can install inline to try and increase the flow round the system in case it is not man enough.

Dickspanner

[toomanytoys]

thats lucky then.... hope its sorts it....

[dickspanner]

Well I decided to build a test rig outside the crewcab using a T4 radiator I had to determine if the engine system was doing as it should and it was, the thermastat opened correctly and the rad got hot etc.

Jacked the rear up and tried bleeding the system, there was some hissing from the rad and I got water etc. Got the rad hot tonight but the electric fan did not kick in and the rad got too hot to touch. Now I do not have the rear engine part of the harness wired up hence no temp sender on the engine on the VW circuit but the temp reading is from the cossy harness. Would this stop the fans kicking in? or do they have a supply to them and run from a stat on the rad only?

I will have a look in my haynes comic later today

The heater got a bit warm but I still feel it has airlocks in the system. I will try again tomorrow night by jacking it up again. The rear heater unit works but I have no control knob for it, so got to source one of those now.

Another problem I have is the fact I have no servo feed at the moment so the brakes are really poo on the crewwy at the mo and I still have no reverse.

The good news is my second belly button has stopped weeping though.

Not sure if I want to lay out for the jag pump yet as it will only pump the heater circuit and not the rad circuit.

Dickspanner

[toomanytoys]

"short" 2 of the connections in the plug on the rad switch... if the fan doesnt run then there is a fault somewhere.. fuse/feed/fan....

heater, could use a smaller (aux) pump off VR6, TD t25, some mercs etc... or a new one from merlin motorsport (IIRC) is about £90

Rear heater???? disconnect and blank....

[dickspanner]

Rear heater is in the box where the bench seat will be and is controlled from a 3 position switch on dash. Happy to leave as is with that one.

The shorting out will be tried tonight. I presume then if the thermoswitch is working correct then there should a 12v supply to one side, the switch then to the fan then earth. I would presume it would be perm supply rather than switched? I will pick up my comic on way to work and have a read at lunch.

[toomanytoys]

Yeah, if the switch is 3 pin it has 2 speeds.. IIRC... middle is common... it will either work or not.. maybe check there is power there to start..

[dickspanner]

OK I have that on my list of things to do tonight.

Trying to decided if I should put a temp sender on the rad as well and connect that to original VW temp gauge in dash to get feed back from the front end as well as the engine side as the engine seams to be running at 95-97 at the moment and I need to keep it controlled.

Think I am going to install a manual over-ride switch on front fan as well for driving in France so I can have it running constantly to keep it cool, and may even install a lower temp change thermastat as well to try and prevent cossy motor cooking.

I have copied a question from Technical into this thread for completness of people reading this to allow all info in one place but the question is as follows

Quote

'I am going to ask a real skool boy question here to to reassure myself.

Should the hot water from the thermastat discharge be fed to the top hose of the rad and water in to the engine (from Rad) should be fed from the bottom of the rad?

Then on which of these two pipes in the engine bay should the expansion tank be connected?'

Double checking my install.

Trying to get info from Cossy forum at the moment about getting a vacuum to my servo as the brakes were a bit 'Ester Ransom' last night.

If I do manage to get all this done tonight the mechanic will MOT it tomorrow for me.

Dickspanner

[dickspanner]

What a night, what a night.

Quite chuffed with my start of the night, the list had only five items and I thought whopeee, its going for a mot tomorrow defo. I called and collected my pump and after a bit of investigation I determined which hose it was to be connected to. I looked at the rad thermoswitch and quite correct Si there was three wires and when shorted it showed both speeds to be working. I am going to put a relayed supply to the rad fan so I can put power to it independantly to bypass thermoswitch.

So on with the big job, the chuffin reverse. After stripping the assembly down I could not understand what the problem was. A quick call to Aiden 'The Man' Talbot and the night turned out worse than a worseer than worse night. The box I have is a 4 speed and I have a 5 speed linkage. Buggery bugger bugger. The next step was to get a 4 speed selector but the problem was my floor pan is sloped and the 4 speed selector is flat with the selector bolted though the floor. So it was either all engine out and a gearbox change or modify a 4 speed selctor. The latter was chosen. 20 mins Aiden said 20MINS. Phah. 2.5 hours later the selector box was fully modified and bolted up into place.

At this point I spat my dummy and wheeled it back into my lock up and called it a night.

So hopefully tomorrow I should be able to adjust it all up and have a reverse. I am not sure about the height issue and throw length and may still have to use my modifed onion holder. We shall see.

Piccies to follow.

Just wanna get the thing chuffin MOT'd now

Dickspanner.