During the test drive I had already noticed the excessive backlash of the steering. Other than that, everything seemed to be OK. The car came fresh from the periodic check of the Road Traffic Licence Agency; it has a stainless steel exhaust system and 5 new TRX tires. It was free of corrosion and the (original) paintwork looked like new except the bumpers and the front spoiler which had been touched-up in a quite unprofessional manner.
Altogether: it was a worthwhile investment provided one could do all the required repairs and improvement oneself. And this was exactly my intention.
The following jobs (with comments) have been completed in the meantime:
- Eliminated backlash of the steering gear (Adjustment)
- Left side power window repaired (replaced broken wire rope) (Pictures), new lower rubber stop
- Removed seats and centre console and cleaned complete interior, cleaned carpets in passenger room and trunk, refreshed leather with care products from Leatherique
- Restored original position of driver's seat. The previous owner had placed it more to the back because of his body height
- Removed radar alarm. This was well camouflaged with the sensor hidden behind the front grille and the alarm in the ash-tray. The whole electric cabling was dubious
- Removed unnecessary cabling (Battery area, trunk, AC fans etc.). Radio antenna re-connected to original cables. Unfortunately, the original switch for operating the telescopic antenna is no longer in use because of the installed fully automatic type
- Installed daylight driving lights. The flashlights are now permanently on with reduced voltage whenever the engine is running and the main beams are switched off. This is to avoid the ugly and aerodynamically disastrous frog- eyes popping out during the day, whenever driving with lights on is compulsory (Italy, Austria, Scandinavia...)
- Repaired engine compartment light
- Produced key for glove compartment (lock is from Audi!) and complete set of car keys duplicated. The car came with only one key each for doors and ignition
- Manufactured new vent controls (brass). The original plastic components were all broken and had been repaired in a more or less non-professional way. Genuine spares are not available (Pictures).
- Refreshed coloured dials for AC controls
- Made proper installation for radio set including correct wiring. Eliminated excessive stand-by power consumption (permanent live for anti-theft system only). After this modifications and the removal of the radar alarm, the battery is no longer being drained.
- New wiring for engine bonnet opening solenoid without fuse because of 60 Amps current draw. Following the original wiring diagram, the fuse (25 Amps) must blow. With the fuse blown, there remains a 7 Volt supply "through the back-door" resulting in the fact that the solenoid operates only with the engine running (approx. 1 Volt plus).
- Replaced wheel hub emblems
- Eliminated oil leak of the timing chain tensioner (replaced O- ring), made new gasket. Adjusted tensioner for correct chain tension. With regards to leakages the inspection authority must have closed both eyes (the car would never have passed the check of the Zurich authority!).
- Sealed ATF- leakage at the transmission (replaced O-ring at the vacuum actuator), added 1 l of ATF
- Aligned and re- positioned front bumper
- Air bleeding and re-filling (R413a) of the AC system. No leaks could be found!
- Front spoiler and front- and rear bumpers re-painted
- Manufactured and installed instrument cluster light rheostat. The original one was simply removed and bridged.
- Replaced kick-down- switch for automatic transmission (new contacts in existing housing). Could not find suitable new switch, however a similar type from the same manufacturer wit identical set of contacts.
- Body polished and waxed with products of Swissvax
- Rims cleaned (inside). Doing this I have noticed that not all four tires were correctly sitting on the rims
- Tire of the rear right wheel re-fitted and balanced
- Manufactured new adjustable foot for the right flash lamp (copied from the left lamp). Instead of the temporary solution with flat shims
- Tubular chassis on the right hand side cleaned, anti- corrosion treated and painted
- Repaired sensor- switch for heated rear window and booster relay installed. The electronic switch does not look to be designed for this kind of high current. Part of the printed circuit board was burned
- Handbrake adjusted
- Sealed second ATF- leakage (new O-rings for refilling tube)
- Sealed cover of the exhaust camshaft rear left (made new rubber gasket)
- Cleaned and checked fuel injectors. Re-installed with new O-rings
- Made new rubber stop for the left rear exhaust pipes. The left pipe's position was higher compared to the right where the stop was properly installed
- Replaced voltage regulator of the lower alternator. After certain time of driving, the radio started to switch off and on again repeatedly. After a lengthy investigation the reason turned to be a sporadic over- voltage in the electric system.
- Synchronised left and right cylinder banks. There was not enough brake assistance under idle conditions and the warning light was frequently on. Reason: the left side throttle was too much open and thus lowered the vacuum in the manifold.
- Replaced injectors of cyl. Nos. 7 - 12. HC- Emissions of the left bank were way above the limit.
- Replaced air- filters, engine oil and oil- filters to create a base for future regular maintenance
- Ignition system overhauled: New ball bearings for distributor shaft, repaired and greased stuck centrifugal automatic advance, new gasket and O-rings. New ignition wire set. Correctly set and activated the switch for delayed idle ignition timing (CH- emissions control!).
- Replaced all radiator- and heater hoses. The upper radiator hose burst during a trip..
- Replaced the minimum oil pressure switch. This was obviously damaged by the splash of coolant.
- Replaced Engine rubber-supports.
- Replaced Flanblocs of lower arms of the front suspension.
- Front brakes overhauled (discs machined, callipers galvanized, seal rings and dust covers renewed).
- Valve clearance adjusted. Renewed all seals of the valve cover area.
- Exhaust collectors welded and aluminium coated.
- Checked / overhauled starter motor.
- Replaced all V-belts.
- Spark plugs replaced.
- Replaced micro- switch for late ignition timing (Swiss emissions control system).
- Power window on passenger side repaired (new wire rope plus adjustment of guides and stops)
- Front position-/ direction lights overhauled. Repair of broken glasses (Pictures). Re-installation with clean adjustment to body surface.
- Installed new control cable for driver's side heater command.
- Repair of warm-up regulator (left bank). Tuned heating for bimetallic strip switching point towards lower temperature.
- Front wheel alignment adjusted
- Sensor for oil pressure gauge replaced
- Turn- /Reverse lamps replaced. New rubber seal rings for brake- /taillights.
- Trunk- carpet partially restored.
- Flanbloc for longitudinal positioning of drive train replaced.
- Cleaned and repainted the entire tubular chassis (Pictures)
- Replaced all rubber elements of the rear suspension, the shocks and the stabilizer bars (front and rear) (Pictures)
- Complete overhaul of AC system (compressor rebuilt, dryer replaced etc.)
- Front wheel camber set to factory values
- Speedometer calibrated and sluggishness eliminated
- Distributor cap and -finger replaced
- Sealed all leakages of the air intake system; replaced all vacuum hoses
- R.h. conveyor between air flow sensor and intake manifold replaced (new design Ferrari 412)
- Timing chain replaced
- Replaced both K-Jetronic booster pumps (Check valves now and then not tight; therefore starting problems with hot engine due to vapour bubbles)
- Door seals left and right replaced
- Refrigerant for AC added
- Small dents in car body repaired with pressing technique
- Non-original Becker radio replaced with new DAB+ radio
- Radiator repair. All supports for AC condensator, engine oil radiator and transmission oil ratiator newly soldered
- Overhaul of cylinder head left bank after compression check with low values for 3 cylinders
- Preventive replacement of O-ring seals of the oil ducts underneath of the oilfilters in engine block
- Cooling water replaced by EVANS coolant
- L.h. conveyor between air flow sensor and intake manifold replaced (new design Ferrari 412)
- Relais for r.h. fuel pump replaced
- Coolant hose from pump exit to engine replaced after leakage
