Good morning everyone. I'll now continue the saga of the Jazz. Well, I had a bit of good luck Monday as I rang the factor just before I started cleaning down and putting my tools away. I was not expecting them to answer as it was well after their closing time but the manager picked up (he was doing paperwork I believe) and I was able to order a shim pack for those front calipers - Pick them up around 10 maybe 11 o'clock as they'll have to come through from Glasgow. I rang at around 9 just to be sure they were able to get them and was told "they're here, come and get them" How's that for service!
And here they are, with one of the old ones at the bottom of the picture.
If you look closely you can see that two of them have a tensioning "tongue" (looped over bit) which puts tension on the pad to stop it rattling against the carrier when the pads are installed. These ones are installed at the top so they press the pads downwards - very logical when you think about it, which makes it even wierder that the two old ones, which are not the spring type, were installed at the top. - I've put one of the old ones at the bottom of the picture so you can compare.
Here they are installed ready for the pads to be fitted
And here are the pads in place ready for the caliper itself to be reassembled.
You'll notice the white grease on the pads. I've been experimenting with ceramic based brake greases and I'm not all that happy with them long term when compared with the old Copper grease I used to use. I find these new greases are quite thin in comparison and, when you dismantle at annual service time, there is very little trace of any grease with the pads often being a bit corroded and tight in the carrier. I mentioned this to Steven when I was last speaking to him and he showed me a tin of the grease he uses. It looked much "thicker" so I asked about it when I picked up the antirattle shims and they sold me a tube of the stuff
So far I'm very impressed and I like it a lot more than the other stuff I've been trying - time will tell I suppose.
So now with the front calipers reassembled I gave the hub and caliper a few good wallops with my rubber hammer and, joy of joys, the rattling noise is gone!
Great, This rattle has been what's been annoying/worrying my daughter in law the most and now that's it sorted! Now for the rest of the service. Oil and filter change went well with a new ally washer fitted to the sump plug and the air filter - that's the ribbed casing on the right of the next picture - is a 2 minute job even including blowing out the casing with compressed air. This filter is strangely small so I renew it every year and it always looks as if it needs it. Maybe one of their motor cycle chaps designed it?
Now with the front brakes, oil and filter changed and front suspension/brake lines/etc checks all done I can put the front wheels back on, lower the car to the ground and fill the sump with oil. As I'm waiting for the oil level to stabilize, before finally topping off to the full mark, I do the spark plugs. This car does around the 8,000 miles a year and uses standard plugs so I do them every second year. It's unusual in that it has 8 spark plugs, two per cylinder! Apparently it fires one slightly before the other to achieve a more complete burn and so achieve better economy? The problem, not that it's a very big one, is that there are 8 coils to go wrong (non of ours have though) and 4 of them are tucked down the back of the engine and quite difficult to access if you don't have a comprehensive tool set. By the way, apparently it's not unusual for the rear plugs to be ignored due to them being "a hassle" The engine will run happily with just the front plugs being changed but it affects economy if the rear plugs aren't firing. 2008 (the year this car was manufactured) was the last year this IDSI engine with the 8 plugs was used, after that they started with the VTEC engine which, more conventionally, has "just" 4 plugs.
Here's what the engine looks like when you open the bonnet
The cover comes off quite easily by removing those two little domed nuts and wiggling it free of the inlet manifold runners
Now you can see the front 4 coils nestling between the inlet runners, held in with just one little bolt.
Looking down the back of the engine you can see why some people don't do the 4 rear plugs. That's the square black top of one of the coils nearest the camera, can you see any of the others? No? That'll be because I haven't yet unclipped and moved the wiring loom to gain access - I hate moving wiring looms as it sometimes results in broken wires.
Getting the front plugs out of their quite deep holes is pretty standard stuff and my magnetic plug socket is a great help. Tackling the rear ones is a bit of a different "kettle of fish". The plugs are down quite deep holes but the brake master cylinder reservoir gets in the way for the No 1 cylinder so you have to fit a short extension to the socket, feed it down the hole and then install another short extension and ratchet on top of that to be able to undo the plug. The other three are easier as there's less fiddling but it's still a bit of a Pfaff! Then, of course, you've got to install the new ones without cross threading them. I must admit not a problem for me, but I've been doing this sort of thing for years, could be quite difficult for an inexperienced DIYer though? Here's the tools I used
Here's all 8 of the old plugs
It's very interesting, or so I think, to compare their "business" ends.
Above you can see two taken from the front mounted plugs and two from the rear ones. Notice that two are more carboned up than the other two. This is consistent with all 8 plugs - ie 4 look as if they are burning a "richer" mix and 4 look "leaner" I'm guessing the 4 "richer" ones are the ones being fired first and the 4 "leaner" are the ones being fired slightly later so are igniting, or reigniting? who knows? an already partially combusted gas? Fascinating eh? mind you I do think 8 plugs for an every day "cooking" engine is a needless expense. Wouldn't begrudge it so much if it were an Alfa engine?
Well, This all seems to be going quite well now, just the pollen filter and the rear brakes to look at and she'll be ready to go down to Kenny's for those front arms.
The pollen filter is one of the easiest I know of to do. Open the glove box and you see this
With your hands pull the bottom shelf towards you and out and now you can see the white plastic cassette which contains the filter element. Hook a finger round the two little tabs, one on each side, and pull.
The cassette pulls out towards you and it's just a matter of lifting the element out, sliding the cassette with it's new element into place until tou feel it "snap" into place and sliding the lower shelf back in until it "snaps" into place - wonderful, nothing except your fingers needed!
Ok, just the rear brakes and a safety check on rear pipes ans shocks etc to do. Jacked the rear end up and, oh dear, the O/S/R wheel doesn't want to spin. That disappoints me because I put a new caliper on that wheel last year as the old one was seized. Surely it's not going to be the same problem so soon? Luckily it wasn't, just somewhat dirty and partially seized pads - disc looks a bit corroded and "rough" though, probably due to the seized pads meaning this brake has been doing nothing for some time? Cleaned up lovely and lubed with the Granville, pads slipped back in just grand. These rear calipers have a flexi spring which serves to lightly push the pads against the caloper carrier and this could do with being renewed as one of it's "arms" is missing - it'll work fine "as is" though, I'll pick up one next time I'm in at the factors. N/S was fine so just needed a clean and lube.
So, all done, or so I thought. Made a nice cup of tea and sat with my "clean" slightly oily rag which I use for cleaning my tools before putting them away, cleaning the tools I'd been using and putting them back in my tool chest. Manista'd my hands and went for a shower, because I was filthy. Came back down and thought I'd better test drive the car to make sure the "rattle" was truely fixed and oh deary me, a terrible rubbing noise coming from, somewhere! My best guess was N/S/F. Oh to hell with it, I've had enough for today, it can just wait for tomorrow!
Well, it's another dry day but quite overcast and rather cooler thank goodness. Into my car doing clothes again and yes there is a wee noise from the front wheel but nothing like the noise I was hearing. Spin up the O/S/R and there it is. Closer examination shows the rust on the disc to be the problem so I dismantled the caliper, pads and carrier then removed the disc and ground away all the crusty rusty bits with a disc (just like I did with Becky's fronts if anyone remembers that?) Reassembled it all and that cured that! Disappointingly the slight rub at the front was due to one of the new anti rattle shims being poorly made. Luckily it was the same as one of the old ones I took of so I just swapped it out for an old one and that sorted that. Both N/S wheels were spun but no noises heard. A wee drive down the road confirmed all was now good with not the slightest trace of that rattle!
I've never been very happy with the hand brake on this car, it just doesn't hold very well. Many people have now told me it's a common MOT failure on them and I'm wasting my time expecting to improve it much. I'm going to have a closer look at it all and the hand brake adjustment when I get that new caliper spring plate.
By now it's lunch time on Wednesday so I give Kenny a ring and he says I's manic stuff Jock, we are unbelievably busy just now. That's the same story I got from Steven, wonder why everyone is getting their cars attended to just now? Anyway he said "how's about next Tuesday"? Oh, I'd hoped I could get it done by the weekend so I can drop it back at their house for Saturday morning when I'll have to go out to water the plants anyway. "Just a moment Jock" and I could hear a conversation going on with Ryan, his son, in the background. "Bring it in very first thing Friday morning and leave it. I'll see what we can do". I really can't ask better than that and I'll be very surprised if they don't do it. Looks like an early rise for me on Friday then?
Just the mystery of the missing shims and the over liberally applied Copper grease to solve now. I feel I should involve Mrs J as she reads endless Miss Marple and Poirot type books.