vonslack

So I decided to make a start on fixing the rotten foam seals in my heater yesterday. I managed to remove the duct from the fan to the heater so I could get to the hot cold flap. Also while it was apart I turned the motor upside down & oiled the bearing on it that squeaks (no squeak for now) & replaced the bulkhead seal. I used some off cuts of lino & double side carpet tape for the heater flaps. Initially my new home made seal was a bit tight so I took it out & trimmed it down. Now at some point while I was doing this the hot cold control cable got bent up at the dashboard leaver end, so I had to dismantle the middle of the dash to straiten this out. Got it working again. Seemed nice & smooth but when I went to try it this morning it was really stiff & the control cable bent up again!:bonk: Is it worth straitening this out again or should I just get a new one, if so from where? Could it be that the new seals are still to tight and need to be trimmed down again? Any advice would be appreciated as I would really like to get the heating working before Winter sets in. Thanx.

Replacing the boost return pipe is a good Idea if it has not been deleated properly, but it sounds like you have got a boost leak and or the charger needs a rebuild. I would have a look around the engine bay at all the hoses between the charger and the throtle body. Also check the vacume hoses while your there, with the engine off and with it running. You could also use the MFA to get an idea of how much boost you are getting. I think there is a how to on here somewhere, if not go to the matey matey G60 guide. Good luck.

Progress! Well somthing I did last week worked! Now getting up to 35 MPG and only a little smoke:cheers:

If the carbon canister has been deleted make sure it has bee done properly, I think there is a how to on here. Have you checked the resistance on the coil? Is the vacum hose exactly 1M long between the inlet manifold & the ECU. Can you hear/feel the ISV pulsing?

I thought I had a faulty fan/fan control switch it, would only run on no. 4 setting turned out to be the thermal fuse that is soldered inside the fan motor housing. cost less than a pound from maplins.

Have a look at the matey matey beginers guide to the G60 http://www.google.co.uk/webhp?source=search_app#

Thanks for the advice guys, I tried disconecting the lambda probe the other day with the engine at opperating temprature & didn't seem to make any difference parked up blipping the throtle. Should I try driving the car with the lambda probe disconected to see if the smoking stops? ECU is standard. I checked the ECU hose today, ( that the garage had fitted), & found it had an extra 7cm on it! So I trimmed that back. I have now checked the earth strap on the gearbox & that is in good order with a low resistance. Earth to the plug for the lambda probe/plug isnt so good So i'm going to give that a good clean up next weekend. I have added an earth strap between the bolt for the coil bracket & the cylinder head. Cleaned up the connection on the green wire on the coil it was filthy where the old coil had been melting/leaking over it, will check the continuity & resistance to the ECU next weekend.

Iv'e been having some issues with my 91 G60 started off being very lumpy on tick over this was fixed with a new set of vacum hoses, ( although it does seem to still go up or down by 200 rpm at tick over). Felt like it was going to cut out before though because it was so bad. Garage told me it needed a new fuel filter & some injector cleaner before the car could be tuned up. So I took it away & did this also replaced the dizzy cap, rotor arm & knock sensor, (cable was rotted). Took the car back to the garage for tune up, emissions found to be lean 0.21% reset to 1.15% blue temprature sensor found to be faulty so replaced & reset co2. Fuel pressure also tested 2.6 bar at tick over worn at uper limit but ok. The car now seems to be running very rich MPG and performance are down so I stared investigating I found the coil was on the way out so I have replaced it checked the micro switches on the throtle both work vacum hoses have not poped off. I have tryed to check the lambda probe also but seem to be getting an eratic reading between 0.3-0.6V, it should be a steady 0-0.9V pulse? Will test again with a more reliable test meter next week. The probe on mine fell apart! Tryed reseting the ecu by disconecting the battery and touching the wires together. Had a look at the spark plugs which are sooty. Car seemed to run better for a day or two after I cleaned plugs fidled with the lambda probe plug and topped up the oil. But back to being smokey again now, any Ideas? Want to get it fixed so I can go enjoy the sun! The car Has a rebuilt supercharger de-catpipe with jetex system K & N panel filter. Normaly leaks a little oil but dosn't burn it.