Dutton Kit Cars and their owners

So, where did I leave off...? Oh yes, carb stripped, cleaned out and back together.

With the carb strapped back on, I again attached a bottle of clean fuel to the inlet of the fuel pump. Lots of cranking later (probably to refill the float chamber) she fired into life, didn't even need any throttle. Excellent. There is, however, a squeak somewhere at the gearbox end of the engine. A lot like a fan belt noise, but from the wrong place. And there's an intermittent grumble from somewhere. Not loud, but it is a bit of a concern. Anyway, she idles at 1500rpm but with an occasional burble, and appears to give full throttle without a problem.

So, I switch her off and have another go at getting fuel through from the tank. I attached a bottle to the fuel pump outlet and crank over. Eventually, I get some fuel delivery. I think less volume than when I tested the pump straight from a bottle, but still looked like plenty. So I reattach the pipes and have a go at starting.

I do get her to start, but it needs a big boot of throttle. And she won't idle at all, anything below 2000rpm and she stalls. But at least the pump is now drawing from the tank, which is promising. However, once up to temperature the engine smokes a lot through the rocker cover breather filter. Which is a bit of a concern. But I get her up to about 90 degrees water temp and shut it off, as I've only put in cheap 5W30 to oil flush it. I drain this and put in 4 litres of Comma 10W40 with a new filter.

So, next steps...

  • I think I'm going to remove the fuel tank and have a look at the condition inside. If it needs sealed or replaced we'll do that, but it'll be getting emptied and cleaned anyway.
  • Blow through the fuel lines, and replace the elements of the two little in-line filters.
  • Replace a perished vacuum hose on the carb.

Then, move onto the suspension and brakes!

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Comment by Roy Kemp on July 3, 2015 at 21:44

Meh, too late now. If the engine comes out for any other reason I'll get it done.

The CVH is a crap enough engine that I'm almost willing it to grenade itself!

Comment by Adrian Southgate on July 3, 2015 at 21:44

Absolute b'stard to get out mind. Ive tried numerous different options in the past including packing it with grease and trying to hydraulic it out by driving a dowel into the centre (FAIL) drilling.. (FAIL) Gear puller (FAIL- way too small)  

I think I used a dremel to grind a groove into the inner race and then split it and fished the bits out with a magnet, then did the same for the outer, pain in the arse.

Comment by Adrian Southgate on July 3, 2015 at 21:31

Going by the condition of the old clutch you took off the engine I'd suggest doing the spigot bearing, tiny wee thing in the back of the crank but absolutely critical.

Comment by Roy Kemp on July 3, 2015 at 21:28

Ah right. Thought you were hinting it was the gearbox mainshaft bearings. Not checked anything of that nature yet! I aligned the clutch plate using the time-honoured method of a deep socket wrapped in tape until it fits snugly! And no, I didn't replace the bearing.

Comment by Adrian Southgate on July 3, 2015 at 21:25

Same difference.

Have you checked the freeplay in the clutch cable, should be 1/8th at rest. Then try it again.

is the clutch aligned? did you replace the spigot bearing?

Comment by Roy Kemp on July 3, 2015 at 21:14

Adrian - nah, tried that. Wondering if it's the clutch release bearing.

Daryl - probably, although it's a grumble not a knock. Hoping it quietens down now it's got thicker oil in it. The one good thing about CVHs is that they tend to soldier on with knocks and rattles for years until they completely drop dead. By that time, hopefully I'll have found and rebuilt a Zetec!

James - yep, quite happy considering most of the engine ancillaries have been in the boot the last few months! 

Comment by Adrian Southgate on July 3, 2015 at 21:05

Does the squeak go away when you push the clutch down Roy?

Comment by James Doulton on July 3, 2015 at 21:00

That sounds like progress.

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