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Eunos JC Cosmo 2006

December 27, 2006

Have started a little project for a shift light. Will update when its done.
 
December 11, 2006
Repaired hazard lights. Previously the hazards would only work if you physically held the button down. After removing the switch and repairing one of the clips holding the base to the switch body, all is working ok. (The broken clip allowed the springs to push the base away from the switch body and prevent it from latching.)
 
December 9, 2006
I recently developed an intermittant fault which kept blowing cabin fuse 8 (10 amp, "Radio - Meters, Air-Con, Clock").
Interestingly, I found that this fuse doesn't protect the air con (nor the "radio" as I removed the OEM radio system). What it seemed to supply is:
- clock, interior lights, memory for trip meter etc, collapsible mirror function, time delay relay on ignition off function.
I was worried that such an intermittant fault was going to be almost impossible to find as there are numerous modules controlling the components listed above, and to make it worse, many also are associated with the TWS module. So it was with some apprehension I started this fault finding procedure....
Luckily enough, when I decided to look for this fault I put a fuse in and it didn't blow. So I sat up in the drivers seat and thought "Hmm... where to start?". Sitting there, the only real thing within my reach was the interior lights so I gave them a short, sharp whack. Unbelievably the fuse blew so I pulled down the rearvision mirror / interior light assembly and found a wire shorting from the base of the festoon lampholder to the mirror assembly! A bit of solder and all good! What can I say???
 
December 7, 2006
Continuing to paint and clean as much as possible in the engine bay. I've done the ignitor/coil tray, the inside of the guards, the support panel across the front of the engine bay, the back of the headlights and associated brackets, etc. Have also polished numerous components such as the washer fluid reserviour, radiator overflow tank, etc. Will continue as time and inclination allows.
 
December 3 & 4, 2006
Painted and installed the new grille 1 2 3. I wrote up the procedure to successfully paint chrome here.
 
December 2, 2006
Picked up a secondhand grille (1, 2) from Jayson of teamEunos who was kind enough to pick it up for me from JustJap. Thanks Jays!
I'm going to paint it so I'll have to learn how to prime and paint chrome.
 
November 30, 2006
Oil changed @77,794 km.
 
November 29, 2006
Replaced the air horn with twin electric ones (see October 23). 1, 2.
One of the resonators literally fell off the air horn which rendered it useless as the compressed air needs the resonators to prevent it bypassing the horn body. I have taken it up with the supplier who has informed me that, because I allowed it to fall apart, they won't cover it with warranty! Can you believe it that they told me I should have sent it back before it fell apart and that I shouldn't have allowed the part to become "lost" when it did? They said "that's how Warranty works".
 
November 19, 2006
Installed 150 ml of refregerant oil (type) and put the system on vacuum for 24 hours. Installed SP34E refrigerant. (Temp at centre vents 6.4 degrees C.)
The compressor clutch would not pull in and this was traced to the fuse that was installed for the recall. This fuse was very badly melted. I'd assume that this fault should be rectified with the replacement of the compress but I will be inspecting it periodically to ensure further melting doesn't take place.
 
November 14, 2006
Replaced air conditioning compressor. 1 2 The compressor was sourced through REVS for a good price with good service.
Just need to add some refrigerant oil, vacuum the system and regas.
 
November 5, 2006

Replaced positive battery terminal (negative replaced previously).
Set all channels on boost controller to:
Channel 1: .5 BAR
Channel 2: .65 BAR
:Channel 3: .8 BAR
Channel 4: .9 BAR
Gain set to 10% for all channels.

 
November 4, 2006
Finished the installation of the Blitz SBC iD III yesterday with the invaluable assistance of DMRH.
As usual, Dave had an alternative way to connect the plumbing to give better control of the twin turbo set up. I must say I'm very impressed. After completion of the installation we set maximum boost to .9 BAR for a test run (I had only been getting maximum boost of .4 to .54 BAR). Out of the garage - first squeeze of the pedal and .84 BAR. Second run and .9 BAR! Keep in mind that the factory ECU has non-adjustable "boost cut" set between .7 and .85 BAR to prevent over boosting. Can't explain this except with Dave's suggestion that perhaps my ECU has been "chipped". Will investigate further.
 
November 2, 2006
Installed extra ground wires to the alternator and igniter / coil mounting plate to attempt to overcome a slight buzzing through the speakers with the engine running.
 
October 31, 2006
Started to install a Blitz SBC iD III electronic boost controller and Blitz Power Meter iD III. Have done all the installation and electrical connections but still need to carry out the plumbing to the control solenoid. On advice from Dave, there's a couple of ways the connections to the turbos can be made so will be visiting him over the weekend to ensure it's connected for best performance.
Having the MAP hose connected and being installed electrically, I'm using it as a boost gauge at the moment. Interestingly, a feature of the Blitz SBC iD III is that it displays a "peak boost" result. Peak boost I have been able to achieve is .54 BAR, much more frequently between .4 and .45. This is significantly less than what I hope the ECU "boost cuts" at, so am looking for a significant improvement when the installation is completed. 1 2 3 4
 
October 25, 2006
After registration I removed the high level brake light as it was poor quality and had served its purpose of meeting the Regulations. I have now installed a new one. 1 2 3
 
October 23, 2006
Installed new horn as the original ones needed to be removed for the intercooler. 1 2
 
October 17, 2006
Removed and pained wiper arms, replaced wiper blades with the "twin" style (2 blades per arm).
 
October 9, 2006
Installed LED parker lamps. 1 2 Much cleaner look than the yellowish filament lamps.
Am doing some painting in the engine bay to clean it up a bit.
 
October 5, 2006
Upgraded intercooler.
 
October 1, 2006

With the alarm module I installed a "Power Windows Module" so the power windows closed when I lock the car via the alarm remote. To further improve window operation, I installed another control module so I can remotely open the windows. I connected these to the "boot open" feature of the car alarm.

Replaced TWS module.

 
September 30, 2006
Installed a front strut bar, purchased from dmrh.com.au. The bar is one piece aluminium construction and of very high quality. 1 2 There is a noticeable increase in rigidity when cornering.
 
September 29, 2006
Installed 2 x new hi-flow mufflers 1 2 . Do to the restrictive nature of the stock mufflers (complete with ECU controlled baffles), replacement with "straight through" mufflers eases exhaust flow significantly.
The new mufflers are only slightly louder than the OEM ones, with the turbos, cat converter, and resonators soaking up much of the exhaust sound before it reaches the mufflers anyway.
 
September 23, 2006
Flushed radiator and replaced coolant with a better quality.
 
August 17, 2006
Removed CCS screen and installed LCD monitor. Connected to DVD player.
 
August 12, 2006
Replaced oil and filter @74,966 km.
 
August 5, 2006

Removed dash and cluster and cleaned all perspex pieces.
Results outstanding.

 
July 30, 2006

Cleaned wheels. 1 2 3 4

 
July 28, 2006
Installed alarm activated automatic power window closing module.
 
July 25, 2006
Flushed radiator and installed coolant.
 
July 22, 2006
Replaced air temperature sensor.
Installed extra ground wires to the engine, upgraded the main ground wire between the engine and the chassis, and upgraded negative battery terminal.
 
July 20, 2006
Removed intake manifold, replaced faulty thermostat solenoid (see 8/07/06); replaced vacuum hoses.
 
July 16, 2006
Cruise to the Blue Mountains with teamEunos. Using a bit of water - 1.5 litres over 200 km (edit: replaced radiator cap 18/07/06 with a .9 bar cap 18/07/06 and it seems to have fixed the coolant loss), boost a bit low, intermittent hot start flooding fault noted (grounds to the engine to be upgraded?).
 
July 15, 2006
Installed temporary boost gauge. Need an alternate design for a permanent fixture.
 
July 14, 2006

Got the following work done by my mechanic:
- Replace metering Oil Pump
- Replace diff oil
- Replace fluid and flush transmission

 
July 12, 2006

Removed operation of butterfly valves in mufflers. These were both found to be seized closed and could not have been operating.
Although there is no need for the muffler valve solenoids any longer, if the ECU signal is not restored it will keep throwing fault code 35. As advised by DMRH, I located the wiring to these solenoids where it passes through the body behind the rear passenger seat to the control box mounted above the diff. The solenoids were reading 21 and 37 ohms so there was a problem with the one reading 21 ohms which would have been throwing the code. After cutting the wires I installed two vacuum solenoids behind the seat so the ECU will get the correct inputs. This should solve the problem permanently.

Removed the OEM air box and installed a pod filter. K & N part no. RF 1003 - it has a 3.5" intake and a 10 degree offset which is perfect to clear the bodywork. Installed a "breather" filter to the intake of the air pump as this needs filtered air and originally had an outlet from the air box. When installing the breather filter, the inlet to the air pump can be straightened using a large screwdriver for cosmetic purposes. 1 2

 
July 8, 2006

Went to see Dave from DMRH and he identified and located 3 problems:
- ECU code 27 (metering oil pump)
- ECU code 35 (muffler valve)
- vacuum leak to secondary thermostat causing intermittent vacuum problems - requires replacement vacuum solenoid under intake manifold (this was temporarily blocked off and the performance increase was substantial).

Polishing completed.

 
July 6, 2006
Removed fuel tank and pump to inspect fuel pick up filter.
Replaced fuel filter @ 73,830 km.
Car seems to be running much better.
 

July 4, 2006

Leather recolouring completed for all intents and purposes. I would like to redo one panel on the passenger seat and will do this in the near future.
 
July 3, 2006
Removed the tape deck under the CCS screen and replaced with a DVD / CD / Radio. To connect the speakers and get to the antenna wiring, the rear interior had to be removed. The deck is in and running and I am in the process of recolouring the back seats / console while they are out.
 
June 29, 2006
Removed intercooler and repaired as best as possible. Will stick with this original intercooler for now as it cleaned up to a reasonable condition. Replaced all 8 spring clamps with worm screw drive clamps.
The vacuum system is holding a vacuum ok. I've replaced most of the hoses and rectified the leak. As the only hoses remaining that haven't been replaced require the inlet manifold to be removed, I'll take this off my list and only do when I have the manifold off.
 
This log is post registration. There are details in the Pre-Registration Work Log regarding compliancing, road worthiness, etc.