Hi Forumites,
Well I havent been idle over the last two weeks, I have managed to fit a few hours in on The cat - mostly Sunday afternoons when all is quiet in the Treloar household, and some free time becomes available.
Last weekend I did manage to run all the fuel lnes in the boot and fit them off. It was not so much as a huge job, but just one of those fiddly jobs where you have to have double-jointed everything to be able to complete the tasks. Some of the stuff that was fitted into place had to be removed in order to fit the fuel lines or fit them off - like the swirl tank, it had to come out to fit the line to the main fuel pump - its just a case of too much equipment and not enough space!!
As promised the Earls fittings arrived mid-week and they were the first things to go on - now all the hose sizes and AN- fittings were aligned and the Gods were happy. The fuel feed and the fuel return to and from the tank completed:
The fuel lines to and from the swirl, to the main pump, filter and return line, and then forward to the hard lines all done, and looking good:
That was basically the end of last weekends foray into the shed. This weekend saw me have some free time on Anzac Day to put some hours in, after I came back from the Dawn Service and the march. The kids went to friends and the wife was at work, and so I had a few hours spare before Pat came over. It was time to get stuck into the eletrical. Because I had so much equipment in the boot - like 12 circuits - I ended up doing a spreadsheet with regards to what wire went where and what it was terminated to. The spreadsheet was invaluable in making sure I fitted off the wiring correctly - as long as you had all the circuits listed - and I hadn't!!
I ended up forgeting the reversing lights - !!! I plum forgot them until I saw the double prongs on the indicator bulbs! After a few curses and expletives under my breath (and checking with Hallsey), I ended up pulling out the loose wiring loom, undoing it and them redoing it with two extra wires - 'cause I ended up commoning the signal wires from the in-tank sender unit, and the WMI sender unit - basic mistake and glad I found it - it was a case of too many of the same colour wires, in this case black, and confusing one for another.
So, with the wiring loom rerun, and all taped back up, and the wiring count spot-on this time, I proceeded to fit-off the equipment that was able to be done. First was the windscreen washer pump - I ended up pulling this out of its grommet and solderig some fly-leads onto the motor connector directly and them terminating them into a male 2-piece connector. While it was out, I tested the pump in a bucket of water as it has three connectors - the third connector actually makes is spin at half speed and in reverse - this services the single washer nozzle on the rear windscreen, which I wont have. Once it was all terminated correctly - full speed in the forward direction - I reinstalled in into the tank, and terminated the wiring into the female 2-piece connector. Next to go was the main fuel pump - Bosch make this really easy - 5mm post for the positive with its corresponding 5mm lug, and 6mm for the negative with its corresponding 6mm lug - you cant get them mixed up, it just took some time to fit the rubber boots over the cables, fit the cable ends off, get my hands in there and put the lugs on, followed by the compression washers (both 5mm and 6mm), and then the nuts (again both 5mm and 6mm), and a good tighten with the 1/4-drive socket.
Cables run:
Main fuel pump and windscreen washer terminated:
Also done is a penetration through the floor for the windscreen washer silicon hose, which runs over to the drivers side and runs alongside the WMI hard nylon line (no pics).
Next to be terminated was the fuel tank sender/pump unit. It has fives wires - two for the pump, two for the sender and an earth to ground the whole unit to the tank. Since it had its own connector, it was a basically just soldering and heat shrinking the correct wire on the plug to the correct wire on the loom. I them gave it some mechanical protection seeing as it will live inder the spare, and it was all done:
The only things left to do now are the tail lights, the boot remote release, the WMI pump and tank level sender and the boot mounted number plate light. I have decided to buy new tail lights - from the Mk 4/5 Mini in the UK, as they have a section in the tail light that is dedicated to the reverse light function, not doubling up with the indicators as we do here on our Clubmans - so the light terminations will have to wait. I also need new gaskets as well, so kill two birds with one stone there.
The light wiring is in position and ready to go:
I have also decided to change the WMI pump - I am going to grab a higher psi pump than what I have. The one I have at the moment is perfect for intercooler water spray or even large capacity W2A intercoler pump - but for WMI its really not up to the task. If you take into account the turbs will be running at 16psi the effective water spray pressure is only about 23psi (pump pressure absolute is 40psi) - the nozzles need a minimum of 25psi to atomise properly, so I have ordered a 200psi pump which, believe it or not, is not much bigger than the one I have and bolts up to the same mounting lugs on the tank. Should be here soon.
Wiring for the WMI tank level sender and pump in place:
Also to do is the boot license plate lamp. I have the original, which has been sprayed silver on the inside to help reflect the light upward and onto the license plate. It looked like dog balls on a mouse when I mounted it up!! I want to repaint mine white, so it blends in a little more with the paintwork. Might get that done tomorrow and then refit the boot lid, as the tail lights can all be fitted off from the outside (mostly). Might even look at some flush-mounting LED's for the license plate lighting, hmmm, food for thought there!!
Cheers,
Tricky
The overflow pipe from the swirl tank to the fuel tank is a -4 hose (5.56mm ID), whereas the Earls fitting that I have on the top of the swirl is a -6 fitting (8.9mm ID) - so the hoses/fittings are incompatible. I bought them probably 12-18 months ago now so I must have gotten mixed up or forgotten the correct size. 
