metaruss

I haven’t driven this car at all lately.  I don’t like to drive it in the winter anyway, but real reason is that the starter solenoid was dying.  I knew it would go, since I got the car with no heat shield and the solenoid was all melted.  Well, this weekend I swapped the starter from my old Shadow in and found that my retrofit heat shield was now gone as well.  That would explain that burning plastic smell I was noticing this summer.  Luckily I had bought 2 new heat shields this fall (dealer parts), so I put one of those in along with the starter.

Had a little scare with the Daytona’s engine…thought I blew it.  When I pulled the fuel pressure regulator, the vacuum line appeared to be disconnected.  That may explain why it was running rich, but it shouldn’t run at all at 10psi of boost.  Anyway, that coupled with some apparent oil coming out of the dipstick and the fact that is was missing at idle, I thought I cracked a ringland.  Well, I snugged up the dipstick and after installing the new adjustable FPR, it seemed to run fine.  I did a compression check and it was the same as before: about 130psi on all four.  The plugged looked perfect.  I guess I’m OK, but it still starts missing on one cylinder if it is left idling for a while.  That Dawes Devices A/F gauge has rather dim green LEDs, so it’s hard to see them in the day and I don’t know if I am rich or so lean that I’m off the scale.  I might just install my old Cyberdyne so I can see what is going on.

Since it is an early-style T1 intake, I had to use a universal adjustable fuel pressure regulator from FWD Performance.  I managed to install it in the same location as the stock unit by grinding-out part of the bracket to clear the return line fittings.  I also had to bend the short pipe for the return line on the fuel rail slightly to clear the unit.  The regulator has 3 fittings: two -4 AN fittings on the bottom (outlet in the center and inlet to the side) and a 1/8″ NPT pipe fitting on the side for a pressure gauge.  I was lazy and just used two brass 1/4″ flare fittings for the inlet and outlet.  I placed an o-ring at the base of the flare fitting threads, which sealed the fitting to the regulator housing.  I also used Teflon tape on the threads so the threads were not so loose.  I then wedged a piece of aluminum between the two fittings so they would not turn when I installed the rest of the brass pipe fittings.  I enlarged the hole in the stock bracket slightly and used the 1/4″ NPT street elbow to mount the regulator to the bracket (between the elbow and flare fitting).  A 1/4″ NPT to 3/8″ hose adapter was mounted to the elbow (inlet) and a 1/4″ NPT to 1/4″ hose adapter to the center flare fitting (outlet).  In order to the fuel gauge fitting to face upwards, the elbow is rotated such that it is pointing somewhat towards the valve cover, similar to the stock regulator.  It’s a little tight between the two hose fittings, but it works and looks decent.

Haven’t done much due to time constraints.  The gas mileage is really poor, maybe due to the stock FPR being unable to dump off the extra fuel from the Walbro 192 fuel pump.  Time to put the adjustable unit in, I guess.  I also bought new GM “WeatherPack” connectors for the coolant and air charge temp sensors.  They both have broken tabs and the coolant sensor code keeps getting set.  I will also be stripping the interior from a fellow club member’s ’86 Laser with the same interior color.  The Daytona’s interior has many broken parts, so hopefully I’ll be able to get one good interior from the two.

Goodbye.  Jason came and picked up the old girl today.  I stripped everything off that I thought I could use for the CSX or maybe sell at some point.  The power train came out fairly easily through the bottom.  I will probably put it in the CSX before that motor seizes, while I build up a good one for it.  Well anyway, it’s all over now….

Fixed a few odds and ends on the days I had off from work.  The big thing was the driver’s side door.  It has a new latch, new pins and bushings, and I repaired the door jam wiring.  The window still gets cocked funny on the way up, which causes it to hang up.  The rubber is in really bad shape, so I’m sure that is not helping.  It’s nice to have a fully-working door, though.  Removing the lower door pin is a real PITA.  After trying several approaches, I had to Dremel part of the bottom tip off so that I could get a C-clamp in there and press it out.  There is no way to punch it out with those damn Turbo Z ground effects in the way.  I supported the door with rope strung over the garage ceiling rafters, looped through two holes in the door frame.

Got the fuel tank to stop leaking, finally.  The lock ring was definitely not tightened all the way, but I decided to drop the tank anyway and fix it right.  The gasket was still in good condition, but I flared the sealing surface out a bit to make it squeeze the gasket harder, just in case.  Also fixed the alignment tabs so the sender was oriented properly.  I still need to do something about the connectors, as the gauge never shows full and I never get more than 10 gallons in when empty.  There is also a grounding problem back there, I think, which may have something to do with it.

Fixing various odds and ends: fuel gauge sender, rear view mirror, hatch struts, more wiring, etc.  Still leaking gas from the sender gasket, but it’s probably because the lock ring isn’t fully tightened.  Once the tank is near empty again, I’ll drop it and try to snug it up.  I also decided to do a compression test after I noticed that it sounded like it was missing consistently at idle.  Results were 127-130-127-135.  That’s a little higher than I would expect, particularly for a high mileage motor that consumes oil, but I feel better about the bottom end in this thing.  I have a feeling that this turbo may be on the way out…the oil is going somewhere besides on the ground.  The plugs also looked good, though they were quite eroded.  I replaced them with a set of Autolite 64s I had, which should hopefully quell the occasional pinging I hear at part throttle/high boost.  The vacuum lines were a mess, so I addressed those.  We’ll see how it is, but the MAP sensor line was very loose, possibly causing lean-out (who knows).  I put the WCV (Grainger valve) from my Shadow in it, so we’ll see how that effects lag.  This motor idles funny and seems to hesitate when accelerating from a full stop, so I’m not sure what is going on.  Once I get all the fittings I need for my adjustable FPR, I’ll be able to put the 804 injectors in and monkey with the fuel to get the mixture right.  There is definitely something screwy with the mixture on this thing, but it may be due to electronics.  It runs rich when it doesn’t need to and lean in boost on certain occasions.  I’d like to convert it to ’87 electronics in order to unify it with my CSX.  Need to find an ’87 T1 LM for that….

I managed to fix the driver’s side door and the passenger side window (regulator tape cut too short).  The door wouldn’t open because the striker bolt hammered out the steel on the latch housing, causing it to mushroom and bind up the latch itself.  I soaked the whole thing in gasoline to clean the grime, used a Dremel to remove the mushroomed metal, and oiled the latch with motor oil.  The door opens fine now, but still doesn’t exactly “pop” open the way it should.  The worn hinges may have something to do with that.  The doors need weather stripping as well.  The driver’s side window tends to bind sometimes on the way up.  Looks like it’s not being guided properly.

I cleaned the armrest when I put the door back together and it no longer matched the rest of the dirty interior.  So, I took some time to clean the dashboard, center console, steering wheel, etc.  Looks much better now.  I also fixed the power mirror wiring and properly attached the center console to the dashboard.  There are a lot of broken pieces in there, so hopefully I’ll get them from Bill’s Lazer.

Drove it to work today.  I stopped for gas on the way and was greeted with more gas leaking from the tank.  Now it appears to be coming from the fuel sender unit (which isn’t working), so I get to drop the tank again.  I’ll let it run/leak down before I mess with it though.  I fixed the radio-related wiring, so I at least have some tunage now.  I also put the stock intake setup back on so I don’t have to listen to the throttle body noises.  I tried adjusting the door handles (they are hard to open), but they seem to be adjusted as far as they will go.  Guess I’ll have to take the door apart.  I’m trying to find replacement striker bolts, with no luck yet.

I got the fuel pump installed tonight.  I was expecting a battle to get the fuel tank strap nuts loose (I even bought an 8mm x 1.25 die to clean up the threads), but they came off with ease.  The pump has been replaced before; in fact it was even a Walbro unit (stock), which made the conversion to the high capacity unit a bit easier.  The inside of the tank is rather rusty (but is solid), and I found an extra pump intake sock floating around in there.  Also, the inner tray that is used to siphon fuel out of a nearly empty tank had popped off of its mount (probably at the hands of the previous installer).  It took a lot of fiddling, but I was able to pop it back on.  I have a feeling there was nothing really wrong with the old pump, but the tank is in good shape now.  Also, the fuel filler neck grommet was leaking partially because it was ripped up by whoever took it out last.

This car is weird.  Besides the front end issues and all that, the under body is strangely free of rust except for the places it rusted completely through.  Two of these places are the front-outside corners of the floorpan.  This is typical because the front wheels sling rocks and stuff at them.  The other rusted out area is the spare tire well in the trunk, but there is obvious evidence that someone backed the car into something: there are scratch marks elsewhere back there and the rear trailing arm was bent up real bad (I swapped it with the Shadow).  It really does seem like it came from down south.  Unfortunately, the CarFax report only goes back to 1991, so I don’t know where the car was originally bought.  The underbody was coated at some point with that rubberized stuff, but it doesn’t look factory.  Either the rear shocks are original or they were put on after the underbody coating was applied, because they are covered in the stuff!  In any case, it may have helped protect the underbody.

Disclaimer: The projects described in these web pages may use dangerous materials, and components.  This material is intended for advanced electronics experimenters only and may cause your vehicle to be suitable for off-road use only.  The author assumes no liability for damages incurred through the use or misuse of the information provided herein.  This information is provided "as is" and without warranties as to performance of or any other warranties whether expressed or implied.  No warranty of fitness for a particular purpose is offered.