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Mike T

1966 404 Coupé Injection Restoration

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Thanks, it's worked out quite well.  Truth is the interior is not done if you count the sliding glovebox tray and heater blower.  But those are not difficult jobs.  So I seem to recall 😅

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Mounted the glovebox on Saturday. REALLY hard to see under the dash...flat black.  You can see the lock.

Glovebox.jpg

Sunday I cleaned and sorted all my nuts and bolts into the proper sizes.

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Saturday I'm going to rebuild the AEG/KF with a kit supplied by my buddy Peter van Deukeren from the Netherlands.

The tiny bearings:
AEG-Pump-bearings.jpg

The shaft seal:
Seal-for-AEG-pump.jpg

The kit:
Peter-s-AEG-rebuild-kit.jpg

My two AEG PLF 5 pumps:
AEG-fuel-pumps.jpg


And today, because I couldn't find the original clips for the dash pad, I made these out of 1mm thick spare rocker panel/sill material.  They now have to be covered with a thin layer of black vinyl.  They join the top of the soft dashboard pad with the soft A-pillar trims.  Each one has been shaped by hand to fit each side very well.

Dash-clip-replicas.jpg

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It's actually quite inspiring to see this coming together, Mike.  Your attention to detail is going to result in what is effectively a new car, and that's amazing.  It also gives me the motivation to get to work on some of my own stuff.

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Dashboard clips covered with vinyl.

dash-clips-covered.jpg

Passenger side:
passenger-side-dash-clip.jpg

Driver's side.
Driver-s-side-dash-clip.jpg

It was a pretty decent effort, I am pleased with the result.

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Dismantling of the AEG/KF fuel lift pump.

A little bit of electrical tape over the motor's drive pinion facilitated the armature's extraction from the pump body without in any way damaging the original grease seal, which is still supple.  So I will leave it in place and use the same technique to re-insert the pinion through this seal.
Grease-seal-AEG.jpg

The freed armature.
IMG-6262.jpg

Making up some different sized slotted washers in the garage made short work of extracting the tiny drive pinion and nearly as tiny bearings.
IMG-6265.jpg

Armature mounted on a drill in a vise so I could polish the commutator/slip ring with fine emery cloth.
IMG-6267.jpg

Comparison between the armature of my car (4598609) on the right and that of a scrapped Canadian Cabriolet (6800519) on the left. 4598609 has done 83,000 miles.  I bought the entire drivetrain from 6800519 in 1982, and at least the electric motor seems to show the traces of more like 200.000 miles...
IMG-6268.jpg

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Today I pressed the new bearings onto the motor shaft with a vise and then the pinion gear after it was inserted into and through the grease seal in the underside of the motor mounting plate.  Checked the length of the original brushes: 6 mm and 9 mm....too short, so I looked in my spare parts stock and found two new or nearly new ones, both 12 mm long.  Then the motor was tested and it was SO smooth!

AEG-electrical-part-rebuilt-and-tested.j

Next task: the hydraulic part of the pump, which sits below the electrical part.

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Today I reassembled the hydraulic part of the AEG/KF PLF5A fuel lift pump.

Bad surprise: despite the excellent condition of the electrical part of the original pump that equipped my car, the same could not be said of the hydraulic part.  The idler pinion inside the pump chamber was seized to its shaft!  The last time I ran the engine was about 2005 so the seizure occurred after that....I presume after I disassembled the car in 2016.  Also, the lower plate that covers the pump chamber has a regulation valve that is supposed to be removed and checked during a rebuild like this and it too was seized!  Anyway, all was not lost...

...because I have a spare lift pump from a car I used to own in 1981-1985 and its hydraulic portion was perfect.  All it needed was a thorough cleaning.
AEG-comparison.jpg

Cleaning nearly done and the last bits about to go back together....
AEG-hydraulic-open.jpg

And it's together.  I did another dry run test with it all assembled and it sounded good.  I should try a pump test, I suppose, though I have no reason to think it won't pump.
AEG-assembled.jpg

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Wow Mike - you really stock piled parts For this build!  First reaction on reading the hydraulic part was in bad shape was feeling your pain, followed by “Well of course he had a good spare...”  Well now played!

Is the bad one salvageable for an parts or possible rebuild or is it too far gone?  
 

Rabin

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After I had finished assembling the pump that will go on the car - and cleaning the fuel line banjo unions that are now on it - I had a closer look at the seized pinion. 

I got a brass punch and gave it some gentle taps and it began to move.  Sprayed some WD-40 and it moved some more...then I was able to get it out.  Cleaning the shaft and inside of the pinion made it work again when I reinserted it.  It was not rust that caused it to seize.  So I think it could be made to work.  Although the driven shaft seemed a bit graunchy compared to the one I used, maybe graunchy isn't the right word, but at least less smooth.  That too could be cleaned up with a full disassembly.

The seized valve adjuster is a bit more of an issue.  I suppose it could come out if I had the perfect screwdriver for it.  I soaked it in WD40.

The commutator is shot as seen in an earlier post in this thread but a kind soul in Hungary is sending me a spare new one he had made locally, for free no less!  So perhaps one day I could put together a second well functioning pump with what's left.  I also found another nearly new set of brushes inside the second motor....

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No actual work has been done on the 404C for a couple of days but today I ordered:

  1. a new old stock camshaft (specific to the KF2 Injection engine) from Loewendoctor in Germany;
  2. a set of 8 new lifters from Alvéas in France;
  3. a timing chain tensioner also from Alvéas.

The cam was very expensive but I think a new old stock cam will be better than any regrind.

A few weeks earlier I ordered new navy blue lap belts for the car, which should be here really soon.

And a bit after that, some SEV Marchal spark plugs in NOS for the KF2 Injection engine is on its way from Italy.

I hope that's the last of the new parts I will need to get the engine back in shape.  I expect to get both in the next few weeks.

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