Today I started with the starter motor. The unit I removed is disgusting – you can see where the welch plug was leaking onto the casing which made a mess. The starter is also covered in a good coating of grease and oil. I suspect underneath all that the starter is in good condition – I know it works.
Fortunately I have a reconditioned starter to install 🙂
The install is straight forward, just two bolts. There is an earth strap which needs to be installed under one of the bolts to ensure the starter has a good ground.
Next was the Transmission Tube. I removed it because it was in the way when I removed the engine, and I didn’t want to damage it during the re-installation. I put a good smear of petroleum jelly on the end to get it past the o-ring in the transmission, and it slid straight in. I hope the o-ring seals OK as it will be a bugger to replace.
The main engine bay wiring harness was looking a bit tired, so I bought some loom tape. I cleaned the outside using Wax & Grease Remover and then wrapped a new layer of tape over it. I also removed the broken fibreglass heat insulation from the temperature sensor wire, and replaced it with a piece I removed from a 240V appliance some time ago. I also carefully dis-assembled the temp sensor connector to clean out the grease and slime so it is all clean and fresh!
As part of the wiring harness clean up, I removed the regulator wiring for the generator, and added the wiring for the alternator. The alternator wiring is much simpler with a sense wire for the Gen light on the dash, and a battery wire. I used a heavy gauge wire for the battery, and wrapped it in loom tape so it looks like it is meant to be there.
I also started working on the wiring for the headlamps. I have some halogen inserts to replace the LHD sealed beam units. I know they are not original, however when I drive at night, I want to see!
The first step is to find a spot for the relays. I decided to mount them in the fender cavity on the RH side next to the battery. This should make them easy to access if needed, but not obvious. I cut the wires to feed the relays, and then wrapped the loom in tape.
Judging by the photo, it looks like I need to paint a little deeper inside the fender!
Next step is to get some heavy duty wire, in line fuses and globe connectors so I can build the new headlight loom.