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Eunos JC Cosmo 2009
February 2009

Took the Cosmo to Kiama for the weekend - approximately 130km each way. The weather was hot, up to about 37 degrees.
Two things I was pleased with:
- fuel consumption was low (less than a quarter of a tank each way)
- the electric cooling fan / EWP system operated impeccably.
The fans were consistently off during easy driving but activated during a couple of roadwork sections where there was little air flow through the radiator. They also operated for short periods when the engine was under load on long uphill climbs. Overall very satisfying.

However during the trip home the alternator decided to fail. This is repotedly a reasonably common failure for 20B Cosmos but not one I have experienced before. The only initial symptom was the illumination of the dash warning lights.
On loss of power, I pulled over and confirmed no charging was taking place. Hoping a fresh battery would have sufficient capacity, the NRMA was called and delivered one roadside (the existing battery was getting a bit "soft" anyway and I had intended to replace it some months ago). This got the Cosmo 65 kilometres and within a few kilometres of home before becoming discharged to the extent further driving was not possible.
A call for help to Dave Morris had him roadside on the M7 within about 15 minutes! He remains the Cosmo King!
To recap the symptoms of alternator failure and the results:
- 5 dash warning lights illuminate
- these come on faintly at first and go to full illumination within a couple of kilometres
- slight drop in idle speed
- there are no other indications that the alternator has failed
- after some time there will be misfiring under acceleration and a loss of power
- the speedo and tacho gauges dim - the needle illumination dims. At this stage you're about screwed: the battery is down to about 9 volts and shutdown is imminent
- a stock Cosmo (no electric fans, EWP) during the day (no headlights) may expect about 80 kilometres of careful driving (minimal brake light use, light acceleration, no audio, etc) after alternator failure with a fully charged battery.

February 2009

Had a spare alternator that had bad bearings. Thinking it the easiest fix I took it to an auto electrician for new bearings as I wanted the Cosmo back on the road ASAP. Asked him if he was able to do it given it was off a 20B.
One look at the alternator and he said "no worries, it's only a Mitsubishi -- I"ll have bearings in stock for it".
Of course, when I went back it was a different story - "In 30 years I've never seen an alternator with those bearings... I couldn't get any from anywhere. I had to repack them and they might be a bit noisy but they'll be okay."
So I might rebuild one alternator out of the two. At least its not urgent.

March 2009

What better way to turn up to a wedding than in the Cosmo.
But we didn't make it.
Symptoms: it just shuts down.... Maybe after a few kms, maybe won't start.
Looks like something in the fuel supply - pump, ECU, relays, resistors, etc, etc.
So a bus trip and taxi got us there - I bailed out of the Reception to get the Cosmo home.
(Added a good towing Company to the Suppliers list.)

April 11 2009

Replaced fuel pump and added some info here.
It became obvious the fuel pump wasn't at fault after a short drive.
Looks like it was the kill switch, however unlikely that seems.
The kill switch was installed in series with the ECU fuel pump control (switches the negative to the FP relay) so very small load. The switch was double pole and I had soldered across both switch mechanisms making this problem even more remote. However, bridged it out and haven't had a problem since.