My 1st P2 (XC70) Project impossible? Topic is solved

[precopster]

Thanks JRL that's what I supected as per the P80s when upgrading to 900s and 901s

Didn't know the centre speaker was already in there!! Great news. The 2002 S60 T5 donor at the pick and pull had a sizeable factory sound box in the trunk which looked like an extra amplifier and it was definitely factory fitted. Did they have a different setup on 2002 S60s or is that something totally unrelated to sound gear?

[precopster]

Some used rear brake pads with about 90% left from pick and pull were fitted last week (only $5)

Finally received the replacement ABS pump and controller. Will fit tomorrow and report in as I can't book it in for registration until all warning lights are repelled.

[precopster]

Finally I fitted the replacement ABS pump only to find the same error: ABS pump failure. Looked carefully at the fuse locations to find that one of the ABS positions was vacant and had no 30A fuse!! Position 19 now filled with a fuse and all is fine.

A small test drive later and some concerns about the pedal travel so perhaps a good bleed will cure this.

Tomorrow a quick home wheel alignment using straight edges and tape and that should get rid of the prodigious torque steer (tailshaft was removed by me when I fitted the first transmission so this is currently a FWD car)

[precopster]

Got the alignment to 1mm toe--in so was pretty happy with that result as when I started there was 18mm of toe-in.

For ease of adjustment I place the front wheels on a steel galvanised sheet so there isn't much resistance during adjustment.

Next on the list is a/c regas and brake bleeding.

[precopster]

The local Volvo indie bled the brakes however the pedal still drops too low.

When I was refitting the master cylinder to the brake booster the pushrod didn't locate properly on the MC and it must have got bent by overtorquing the 2 nuts. I realised this once I pushed the brake pedal which was jammed up and corrected it however the damage was done.

My indie Romeo is going to drop the subframe and swap over the brake booster next week. This is the first time I've employed outside labour on this project (apart from Henry the doublebug my programmer) however this week I'm recovering from a calf muscle injury that had me on crutches last week so I needed to let go and actually spend some dough.

With any luck at all I'll have her back mid next week.

[precopster]

Brake booster made no change to pedal depression so it may be that the master cylinder has a problem. Also need RHS control arm (will press in Lemforder and Meyle bushings)

On a side note I don't know why Meyle choose Turkey to manufacture their bushings as they aren't in the EEC but that's another discussion..

Mechanic wasn't happy that the car is now FWD so the tailshaft has to go back in to pass the safety check.

[precopster]

Master cylinder was leaking so one from a 2003 XC70 has been sourced. The particular (late) VIN on my car means I can source any master cylinder from an XC70 up to 2007.

Talk about gremlins!!
This car was a repair bill looking for a place to land

[precopster]

Still problems with a leaky booster (hissing noise from the booster disappears when the booster hose is removed and blocked) so another one will be sourced and fitted. One of the mechanics working on this car over torqued the wheel nuts on just one side of the car.

My usual mechanic tried to break the wheel nuts free with a long bar and when the last nut broke free it re-shattered his already previously broken wrist. I felt badly for him as I was with him when it happened.

[precopster]

Driver's side control arm rear bushing was pressed in by me as it was chewed through and failed the safety inspection. I couldn't resist a sale on a shop press so now bushings will be a breeze. I still can't get to the front horizontal bush due to the offset so I'll need to fabricate a jig to reach these rear bushings.

3rd brake booster fitted now. This also hisses and pedal sometimes drops. It seems this car is destined to have faulty brakes!!

The main issue is that all used ones are now 15-16 years old as the 2002 plus boosters were revised so I can't fit one from a 2007 for example. Leaking brake fluid from the master cylinder affects the rubber diaphragm and causes a perforated vacuum chamber.

A Vida check shows the LHD and RHD versions are identical so a new one from FCP will be sourced. That's a AUD$343 item including freight and currency conversion. This is this project's highest single outlay to date. Engine or transmission was about half the cost!!

Good news is the P1332 code for CVVT has gone away (at least for now)

Sunroof has developed a fault where it makes a cracking noise when driven too far back. Sounds like teeth skipping and is quite a racquet!! Perhaps a Vida calibration required as the resting position is also hard to find; seems to close slightly above the roofline.

[precopster]

I finally have tracking advice from FCP today for the new booster after ordering at 4pm Connecticut time last Friday. Hopefully I'll see it by Friday by some miracle.