Aircon
Charge
Cigarette lighter
Defog
Dome
Ecu-Ignition
Engine
guage
Hazard-Horn
This section offers information on how to fix cars and useful things to be
aware of when buying parts. I hope this will save you making the mistakes I
have made and save you trips to the library and buying those dreadful manuals
that you use only once and that say things like "this is too hard for the
home mechanic take it to the garage". It's a mixture of articles about
repairs I have done (or seen done) and links to other web sites that offer technical
advice. If anyone wants to add an article, tips or advice or knows of any good
links please contact me by email.(Ric(at)automagic.co.nz) Our dream is to have
a link to every worthwhile automotive “how to fix” article on the
web. I will slowly add articles to this site as time goes by. Some of the articles
are written for beginners and others will eventually be very technical e.g.
the fuel injection section.
. If you are stuck for advice email us. I may have info that is not put on the
site yet or if you’re very, very, very lucky, I may look in one of my
"zillion dollars" worth of books. And if you’re stuck late at
night, try waiting until the morning – it’s amazing what insights
a new day can bring. Good luck.
All links being checked and updated December 2007
Audi Quattro 90
http://www.20v.org/problem.htm
has great tech info
BMW
http://member.rivernet.com.au/btaylor/BMWText/technical/Engineand ModelCodes.html
superb site with priceless info
http://www.lexam.net/peter/carnut/320parts.html
partial wiring diagram and fuel injection identification for 320
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To help find the cause of spongy/low pedal brakes clamp the 4 brake hoses and remove the clamps one by one.
BRAKE FAULT CHECK LIST
EXCESSIVE BRAKE TRAVEL
BRAKES PULL TO ONE SIDE
PEDAL SPONGY
PEDAL HARD (excessive effort required)
BRAKES SLOW TO RELEASE OR DRAGGING/OVERHEATING
BRAKE FADE
ABS
Assume that the system is under high pressure. Discharge pressure in accordance with the manufacturers instructions before removing any hydraulic line or component.
Do Not disconnect or reconnect any electrical connectors while ignition is on. Damage to ABS Control Unit may result
Treat wheel speed sensors with respect. Speed rings must be pressed into hubs. Hammering, prying or using undue force during installation can effect their magnet values and cause inaccurate information for the Control Module
Often very expensive to fix
Uneven tire and rim sizes on a vehicle will result in inaccurate wheel speed information being transmitted to the ABS Control Unit. This faulty information will cause ABS Lock-Out or erratic operation
If electrical welding on vehicle is required, disconnect the battery first, then the connectors to the on-board computers.
The ABS Unit operates at high pressures (2500 PSI or greater). Use only the manufacturers recommended hoses and components.
Use only recommended brake fluids. Do not use silicone
Taken from http://www.priorreman.com/Tech.htm more info there
Cambelt
Here is a list of interference motors. ie ones where the valves hit the pistons
when the cam belt breaks
http://www.rebuiltautoengines.com/daihatsu-articles.html
Subaru EA82 cambelt instructions at this link Other 1980s subarus could be similar
http://www.economysuperstar.com/milesfox/subaru/service/timingbelt.htm
If your stuck for cambelt instructions email me Ric@automagic.co.nz
http://www.corvetteforum.com/
- The tech tips are 1/2 way down the RHS. Click on park brake adjustment
and a helpful mechanic has an email address so you can ask him questions. Then
click on links to find new and used parts suppliers (USA based).
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Daihatsu Charade
http://www.daiclub.com/index.php?option=com_content&task=view&id=21&Itemid=2
Download Charade engine and chassis manuals online If only it was always so
easy!
B210 Up to mid 1978
B310 mid 78 on
http://www.datsunworld.com
British old Datsun club site with good tech tips
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Engine Reconditioning
In this section I link to specialised information on the inside of
motors.
This page (near the bottom) has links to information from the American Reconditioners
Association which give detailed info on problems its members have had assembling
engines. Also "mid model' changes
http://www.rebuiltautoengines.com/
Anda similar if smaller one from Ashburton , NZ. Scroll down below the cooling
article for a variety of tips.
http://www.engineservices.co.nz/tips.htm
Fiat
NB many Fiats have shorter than usual cam belt change intervals
Dino Enterprises http://www.fiatparts.co.nz/
- fixes, wrecks, answers questions on, drives and does a great web site
on Fiats and Lancers
The Fiat Page http://www.mirafiori.com/
- Great Fiat (Fix It All the Time) site with tech help links and much
more
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Consul
Classic 315 http://www.mcs.vuw.ac.nz/~kris/consul/
- Ford Consul (and Capri) site, some detailed info on hand brake conversions
Anglia
105E http://www.geocities.com/MotorCity/Downs/2640/
- Anglia 105E enthusiasts site. Front suspension mod. Details etc with
tech help links and much more
Model T
woops nothing here sorry
Zephyr
http://groups.msn.com/GaleforceZephyrs/enginerebuild.msnw
the complete package including tech info
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FUEL INJECTION
The first things to check are for any loose wires, disconected plugs or breakes
in the flexible hose between the air filter and the intake manifold.
. The second place to look is the fuel supply. Check the car has petrol and
then listen for the whir of the fuel pump through the filler cap. The pump normally
comes on for a few seconds after the keys turned on and then starts again when
the engine is running. (this stops petrol being pumped everywhere following
an accident where the engine cuts out) If the pumps not going check the fuel
pump relay and the fuses and if the’re ok make sure power is reaching
the pump (often found in the tank). Check the electrical continuity between
the pump terminals.
The next step is to check the fuel pressure. Disconnect the fuel pump fuse or
wire with the ignition off and run the motor or turn the starter to relieve
the pressure and insert a fuel guage via a T junction in the fuel line near
the fuel rail. Start the car or turn the starter and read the pressure. Pressures
vary but 250Kpa (36psi) is not uncommon. If the pressure is wrong it could be
a blocked fuel filter, or faulty fuel pressure regulator on the line that returns
fuel to the tank.
Also check around for any loose vacuum hoses and leaks at the inlet manifold
Other pre checks are the rest of the fuses, earthing points( particualy on the
engine block), and check that the fuel injection wiring loom is not too close
to other wiring (say 8cm).
You can try disconecting some sensors. I located a fault in a Nissan Sunny by
disconecting the oxygen sensor. AOther ones to try would be the knock sensor
or the temperature sensor.
The next step is to get the fault codes read. Prior to 1996 this can normally
be done without a scan tool.{ see links}
http://www.autoshop101.com/
Go there and then click on "technical articles" on the LHS then OBD1
or OBD2 Contains good basic info from Toyota. Explains the basics well.
http://www.picoauto.com/automotive-diagnostics-videos.html
Excellent site by Pico Oscilloscopes with high tech info for mechanics with
oscilloscopes. Absolutely A1 Contains real examples of fuel injection problems
and how they were solved as does the following site.
http://www.tiepie.com/uk/automotive/
http://www.troublecodes.net
lists fault codes for many models and how to get them (or did, now I cant find
them) but massive must see fuel injection site including reviews of scan tools
http://www.dalidesign.com/hbook/intro.html
DEAD LINK DEC 2007
explains the basic components of fuel injection and gives a flow chart and ideas
on an approach to diagnosis
http://www.lindertech.com/docs/ignstd.pdf
waveform scope ignition info
http://www.BatAuto.Com
a wide variety of tech info including fault codes for ecu’s
excellent heavy duty OBD11 info – a must for serious mechanics
http://www.OBD2.com/sps/data/sps.htm
Sell a wide vareity of fuel injection tools A handy place to pick up a few tips
http://www.autoecms.com/main.htm
not much here Its just here for my personal use
http://www.smogsite.com/articles.html
sophisticated fuel injection diagnostic theory Detailed tech info ABSOLUTELY
FIRST CLASS
http://www.bba-reman.com/auto-mine/index.htm
tech info, a forum to get answers to your problem, a good list of common faults
with EFI
http://www.sdsefi.com/tech.html#FAQ
comprehensive theory (advanced and basic)as well as info on installing theirftermarket
fuel injection systems
http://www.auto-solve.com/mech_inj.htm
Descibes function of all KE Jetronic components
http://type2.com/bartnik/tech1.htm
explains the function of the components of L-Jetronic fuel injection
http://www.robisonservice.com/servicedep/rover_trouble.asp#87
Land Rover fault code info
http://www.volvoclub.org.uk/tech/service/850/Waveforms.pdf#search=%22oscilloscope%20injector%20pattern%22
32 page article on injector waveforms and cicuitry. Very good
Hillman Imp
http://www.imps4ever.info/
info on imps, this site is great
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Honda
Some auto electricians are having success re-soldering dry joints inside those
expensive relays.
Honda City
On the 1984 model the brake lines and the petrol lines run in the sills. There's
even a plastic line in there, so look out if your welding. the chasis's sometimes
crack where the lower inner suspension bolts on.
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If the steering rack ends are over tightened they tend to snap where the ball
meets the rod.
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Japanese relay and fuse translation
I have more pics and translation than is here so give me a hurry up if you need
it (Ric@automagic.co.nz)
Aircon | Charge | Cigarette lighter |
|
Defog | Dome | Ecu-Ignition |
Engine | guage | Hazard-Horn |
| 1 | 2 | 3 |
| 1 | 2 | 3 |
| 1 | 2 | 3 |
| 1 | 2 | 3 |
Aircon
Charge
Cigarette lighter
Defog
dome
Landrover
http://www.robisonservice.com/servicedep/rover_trouble.asp#87
Landrover efi fault code info
I can borrow aworkshop manual for SeriesIII landrover. Email is Ric@automagic.co.nz
Left Hand Threads (or should that be threats!)
this list is not exhaustive and beware of previous mechanics swapping parts
(ie righthand for lefthand)
Please email teaboy@automagic.co.nz with any additions and corrections.
To determine the left and right hand side of a vehicle stand behind the vehicle
and look to the front. Usually in N.Z. the RH side is the drivers side.
Austin FGK truck LH wheel nuts
MK4 Cortina viscous fan centre nut
Toyota Hiace 2ton truck 1990 L.H.wheel nuts.
Ford Econovan L.H. wheel nuts. (some????? or all??)
Nissan Homy 1988 diesel rwd the 27mm nut on the mainshaft inside the gearbox
(And I’m told other Nissan rwd gearboxes)
Vauxhall Viva and CF Bedford viscous fan nuts
Ford laser 1994 right rear wheel bearing nut
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RX7
http://www.iluvmyrx7.com
has workshop Rx7 manuals on line
Mazda626
http://homepage.ntlworld.com/dorothy.bradbury/probemx/p_p4.htm
wiring diagram of distributer 93/94
Valve Collets e.g.323
The silver ones go on the inlet and the black ones on the exhaust. They are
a different size on the inside.
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Mercedes
http://www.mercedesshop.com
one of the worlds most comprehensive merc sites
Direct link to 300E water pump relacement at above site
http://www.mercedesshop.com/shopforum/showthread.php?t=127966
Pic of 300E fanbelt layout futher down this page http://www.mercedesshop.com/shopforum/showthread.php?t=41023
And this kind man has published a list of replys to readers mercedes repair
questions
http://www.benzdoc.com/
Mini Electric
http://www.carrott.org/cgi-bin/twiki/view/ElectricMini/WebHome
This electric mini is being built now in NZ. Links to the blog of daily progress(25/808)
http://www.ibmwr.org/ktech/
E xcellent BMW tech info
http://www.teglerizer.com/triumphstuff/techlinks.htm
info on Triumphs and MGs and SU carbs
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Mitsubishi
6 bolts on the back of the crank =1800 4G62 motor or 2000cc 4G63 motor
5 bolts on the back of the crank = 1600cc 4G32 motor or 1800 4G37
Different autos have different diameter ring gears so sometimes when changing
the gearbox you have to change the starter. Some disagree with this and some
don’t. My flywheel had 106 teeth
1979 to1995 4 cylinder Mitsis have the same bell housing pattern
In an auto if the car will not move backwards or forwards suspect stripped teeth
in the torque converter. Stick your fingers in the hole and see if you can feel
the striped teeth. If the car won’t move in first or reverse its likely
to be ????
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Mitsubishi Chariot Auto
To Manual Conversion
If the auto has overdrive or has heaps of wires off it. the auto is always computer
controlled. The computers give heaps of trouble.
If converting an auto to a manual use the vacuum controlled gearbox to save
cutting holes through the firewall for the cable or better still take it to
Budget Mitz Bits in Hamilton 07 846 6015 email Keith@wave.co.nz
They gave me a very reasonable quote for parts and labour.
If the vacuum is not working the gearbox will not go into 5th gear.
Check list for converting auto to manual
Flywheel 3 clutch parts clutch fork starter
Gearbox USE THE ROD CHANGE VACUUM BOX NOT THE CABLE ONE. gearbox mount
gearstick and rods console
gearbox oil
pedalbox and firewall grommets
clutch cable
flywheel and other bolts
Cheque book address and map for the wrecker
Patience
Front exhaust pipe section going beyond the gearstick
The driveshafts can differ where they go into the gearbox
PROCEDURE FOR CONVERTING AUTO TO MANUAL (Mitsi Chariot)
Before starting make sure the auto had enough fluid in it. Check the level with
the motor running. It won’t work properly with out it. Some people claim
that Mitsi trans fluid works where others don’t. I’m sceptical.
Do a ring around and make sure there are no real cheap auto gearboxes or gearbox
computers. I don’t know how you tell which one causes what and it only
has a computer to control the gearbox if there’s heaps of wires off the
box.
Remove the gearbox in the normal way and unless you want oil everywhere drain
the oil first and the torque converter as soon as it’s out.
Remove the pilot bearing by filling it with grease and hammering a tight fitting
drift through the hole. It will hydraulic out. Want grease in your face use
a loose fitting drift. Want to get frustrated use a slide hammer. Like noise
try a die grinder. Want to be a looser try one of those warehouse stones in
an electric drill.
Bolt up the flywheel and clutch . If your paying more than $160 plus Grab Snatch
and Take for the clutch don’t email me. Lift up the gearbox, the bell
housing bolts line up and you use the top gb mount that came with the manual
box. The driveshafts that were in the auto go straight into the manual box.
(usually not always)
Cut a section of exhaust and the catalytic converter out and bolt the steadyrod
part of the gearchange rod to the gearbox and lift up and mark out the bolt
hole pattern under the floor and drill the holes. Wear gogles. Get someone patient
to help bolt it all up – one underneath and one on
top. Weld up the exhaust.
The steering column comes out so the pedal box can come out and be replaced
with one with a clutch pedal. Remove the plastic cover under the steering lock
and put a piece of bolt in where the cable from the gearshift used to only allow
it to start in park. Find the 4 holed plug that came from the gearbox “wont
start in gear safety switch” and short the 2 appropriate wires.
Run a wire from the key side of the coil through the vacuum switch to the “let
fifth gear work switch” on the front of the box with green wires and then
to earth.. The 2 red wires off the box are for the reverse lights. Power to
one from a power “only when the lights are on” scource and the other
to what ever wire lights the reversing lights. Then there’s the lower
flywheel cover, tinware, wheels spanners to clean up…
Fill the gearbox with oil and try and do something tidy around the gear stick.
This will take some time as nothing fits well. Get rid of the old auto gear
change cables and tie up the wiring and you r ready to try. Goes into all gears
except fifth look to the vacuum system. Allow about 2 days from first checking
out the auto to totally finished in reasonable working conditions with good
tools.
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Mitsubishi Galant
http://www.dsm.org/how-tos/tttt/tttt3.html
mitsi idle control galant
http://www.vr4stealth.com/
-site with tech info and pics of these
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CAM BELT BE CAREFUL INFO COMMING
http://www.morgannz.com/
N.Z. car club site Lets hope they make it work soon
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Morris Minor And 1000
Safety warnings
When checking the front suspension the jack MUST BE PLACED UNDER THE LOWER ARM
not under the chassis. Grease the top and bottom outer suspension at least every
2500 miles – a complete suspension arm job is around $400.00 plus GST.
In N.Z.
The radiator overflow hose often drips onto the brake line causing it to rust.
An inline brake booster does wonders for the pathetic brakes.
Lift the floor panel and see if the brake lines are rusted out near the master
cylinder (or anywhere else).
To lift the gearbox in or out rotate about 35 degrees to the right so the top
of it misses the steering rack. Don’t forget the screws through the floor
may go into the crossmember.
A 120Y motor and box make an appropriate (i.e. not over powered) conversion.
The Morris (or was it the 120Y) driveshaft fits in with out cutting and this
determines the front to rear position of the motor and box. The up and down
is determined by the bell housing needing to clear the steering rack. Tip a
Mini or Morris 1100 radiator on its side behind the grill and put an inline
booster (eg hillman hunter?? down stream from the master cylinder. Weld the
exhaust , engine, radiator and gearbox mounts and alter the wiring. Etc.etc.
Not a conversion for the inexperienced.
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Nissan
Nissan Bluebird
Heater radiator replacement (U13)
The heater has 2 plastic pipes that pass through the firewall. these are brittle
and break easily. Here's a few breif tips to a 12-16 hour job. Remove seats
centre consol,radioand speedo surrond. You do have to undo the steel pipe between
the 2 A pillars behind the dash, the plastic piece above the dash and under
the screen, the whole dash. Mark all plugs with different coloured paint or
marker pens. Take good note of how the wires go around various obstacles. You
do not have to remove the air conditioning unit and fan to the left of the heaster
radiator.It is necessary to undo the air con pipe bracket to the LHS or the
heater radiator
Nissan Heaters working on high speed only
There's a resistor on a piece of flat steel inserted in the air duct just downstream
from the heater fan.On a 98 pulsar its just above the passengers feet.
Nissan Laurel
There is a petrol pump “relay box” under the carpet under the front
left passenger seat as well as the normal one under the bonnet.(1986 model)
The 87 skyline has 6 different discs so follow the golden rule - take the old
part with you.back to index
NISSAN PRIMERA– late 90s WARNING
There are two oil filters for different models. One has a 20 mm thread and the
other a 19 mm thread. If you put the 20 mm one on the 19 mm engine it will fall
off but probably not until you’re on the motorway in rush hour. This is
our nomination for the dumb idea of the year award. Does anyone have Nissans
address in Japan so we can let them know what we think.
FILTER NOS COMING
Some primera engines have tiny holes in the oil pipe that feeds oil to the cam
shaft.if the oil is not changed regularily they block and the cam wears down
badly. It happens so often that you will be lucky to find a reasonably priced
second hand one.
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Porshe
Some tech info on 912 Porshes including a full manual. I don't know why this very useful Porshe site is called "Hilllman images"
http://hillmanimages.com/912/home.html
http://www.c34.org/faq-pages/faq-stainless-alum.html
drilling stainless steel advice
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Subaru
Petrol pump problems
The connector behind/under the back seat that carries power to the petrol pump
has a tendency to corrode. Around the motor the fine bolts often go into aluminum
and the coarse ones into steel. (87 18004wd)
Legacy door lock problems
If your Legacy’s door locks insist on locking themselves every time you
try to open the door, you probably have a bad “Lock Remote.” The
Lock Remote consists of a plastic rocker Toggle that locks/unlocks, and a chrome
handle that releases or opens the door. There is an explanation of what is causing
the problem and two ways to fix it. Go to hobiegary@mediaone.net If the site
goes off the net email Ric@automagic.co.nz
EA 82 motor cambelt instructions http://www.economysuperstar.com/milesfox/subaru/service/timingbelt.htm
WRX Manuals Online
Workshop Manual for Pre MY97
http://www.jimclarkeracing.co.uk/scooby/pre-my97/WiringDiag.pdf
Workshop Manual for MY97-98
http://www.jimclarkeracing.co.uk/scooby/pre-my97/premy97.html
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STEREO WIRING COLOURS
SONY - THESE COLOURS MAY NOT WORK FOR ALL SONY STEREOS
Power battery – yellow
Switched power – red
Earth – black
Antenna – blue
ALPINE THESE COLOURS MAY NOT WORK FOR ALL ALPINE STEREOS
Pin 1 red switched power
Pin 4 grey fr speaker +
Pin 5 grey/black fr sp.-
Pin 6 white fl speaker +
Pin 7white/black fl speaker –
Pin 8 black earth
Pin 9 blue power attenna
Pin 10 Blue/white remote turn on
Pin 12 Violet rr speaker +
Pin13 violet/black rr speaker-
Pin 14 green lr speaker+
Pin 15 green/black lr speaker –
Pin 16 yellow battery
Toyota
There is a series of toyota technicl articles at
http://www.autoshop101.com/
(when u get there click on "technical articles" on the LHS)
2E cambelt info
the early and late cam belts are different diameters and the 3E is a different
length. Idler and tensioner different diameters also
KE 10,30,36,70 Diff swaps
The KE70 is about 4'' to wide for the KE36, the KE10 is the same as the KE20,and
has the same stud pattern as old mazdas (4x110mm), the KE10 and 20 will fit
the KE30 and 36 housing if you take 5-6mm off the axles, the KE36has a 4x114.something
stud pattern which is the same as a familia. The KE70 has a stud pattern the
same as EX lancer
Toyota Hiace cam diesel motor
The side cam is an earlier motor with rocker arms and the centre cam motor has
no rockers (the cam pushes directly on the cam follower) but the camshaft IS
NOT IN THE CENTRE OF THE HEAD.
flywheel and clutch are different
engine mounts fitted
both motors fit directly to the same gearbox
in my case the side cam came with no power steering pump and I had to shorten
the pulley to align the fan belts
LABEL THE WIRING CAREFULLY there are some differences
the radiators are different
I needed different fan belts
overall a relatively straight forward engine swap
beware of pricing, at the wreckers second hand motors were $2500 plus GST. A
reconditioned long blocks with a new water pump and cam belt were $2000 plus
GST (at Carr Engine Services 09-620-0020 January 02
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Toyota KE70
This is the rear wheel drive wagon that yours truly has driven for years and
I have heaps of parts for sale (Ric@automagic.co.nz)
Wiring - note 3 yes 3 fuse boxes -by battery, rhs drivers right foot, by drivers
right knee.
The fuse for the tail lights is hidden behind the kick panel by the drivers
foot(RHS). The relay just above it is for the tail lights and mine has never
given trouble.Tthe headlight wiring system is a total nightmare UNLIKE ANY OTHER
HEAD LIGHT WIRING SYSTEM I'VE EVER SEEN. Try plugging in another light switch
if someone will lend you one otherwise email me and I'll post you a wiring diagram
and then if necessary talk you through it over the phoneor expain how to fix
the common problem in the hl switch. Try joining the two parallel slots the
3 pin H.L. relay plugs into. If they leap into life try the hl switch. Do not
start replacing wires down by your riht foot unless you know what your doing.
Many autoelectricians dont. Another common problem is water leaking in over
the circuit board by the drivers right foot.
Parts
T he following parts are different between my 1983 model and my 1986 model.
front indicator lights guards and bonnet, suspension strut where it bolts to
the front lower ball joint, the 83 has a steering box and the 86 a steering
rack, the steering column, the headlight switch. Most other parts are the same.
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Toyota Prius
On line manual here
http://www.autoshop101.com/
Toyota Supra
http://www.cygnusx1.net/Supra/Library/TSRM/MK3/default.aspx
complete Toyota Supra manual on line
Triumph Herald - URGENT SAFETY WARNING COLOUR
A steering rack end broke on one of these that one of my customers did up for
his mistress almost causing a nasty accident. I crack tested the other one on
the other side and two more I bought as replacements. They were all broken in
the same place – where the ball meets the straight bit. The solution is
to fit Triumph 2000 ones. They are a little longer so the end needs cutting
off.
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http://www.triumphclub.co.nz/
double click on the car and your in – adds, how to fit a 180B diff in
your Vitesse etc
TR2/3/4
If you want a slightly bigger motor the Leyland 20 van motor has the same bore
but a longer stroke making it 2200cc.
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Trouble Codes
http://pages.videotron.com/kemp4/
reading fault codes for Ford Probus 93-95 and other Mazda mecs2 motors
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VW Air Cooled
http://www.nls.net/mp/volks/
Very clear technical info
http://type2.com/
repair instructions for air cooled VW, Karmann Ghia, Vannagon Beetle etc easy
to understand
And 49 -83 VW Transporters
VW Variant 1967
The doors on the coup and the car look interchangeable but the HINGES ARE DIFFERENT.
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VW Jetta 2000
some water pump plastic impellors break