Now that winter is over and the weather is nice again, it's time to do some more work on the '02.
But first, I'm long overdue for a catch-up post, so here it is.
With all the cooling hoses off, I pulled the heater box out. The fan didn't work and the heater valve cable was broke.
Pulled the box:
The heater valve and broken cable:
Inside of the old valve:
Lots of WD-40 to break free up the lever/cable clamp:
I used the rebuild kit from Blunt for the Heater Valve, bought a new fan motor off Amazon, and a new Bowden cable from Rogers tii
I needed a solution to mount the old fan to the new motor, this is what I came up with:
I bought some aluminum collars off Amazon and brazed them to the fan. Be very careful, too much heat will warp the fan. I spent a lot of time getting it straight again.
Cleaned up the overspray on the cover and gave it a fresh coat of paint:
I took the heater core to a radiator shop, they cleaned it and checked it for leaks, didn't even charge me.
The heater box is all assembled and ready to go back in.
Unfortunately, I discovered the source of the water leak in my car:
The bottom lip is almost completely rusted away. I'm not sure if I should just cover it up with an epoxy paint and seal it real good, or have a new piece welded in. I'll save that decision for later.
While the heater core was out, I figured I might as well clean up the wiper box, it had lots of overspray on it too:
I got another intake manifold, but didn't like the carb spacer the PO had used, it looks like it was for a 32/36, so I bought a 1/4" thick phenolic sheet and made my own
Who says adults can't play with crayons? Made a rubbing of the bottom of the carb
Used my dremel to cut out the spacer, here compared to what was on there:
The intake holes had to be opened up:
Fresh coat of cast aluminum engine paint and mounted:
Can't put the old carb on it without a rebuild, right?
So apart it comes, crud inside:
Crud in the filter:
Had to make my own gaskets:
And that's where I'll leave it. More to post for the catch up later.
Heater valve repair $92.00
Blower Motor $70.00
Bowden Cable $45.00
intake manifold $100.00
Carb Rebuild Kit $100.00
Weber Jets $50.00
Running Total $9,067.00