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In The Workshop - Engine and Fuel System

 

Prior to its recommissioning, the Rav last ran in 2020 when it moved storage locations. It had been reluctant to start, but eventually fired up and drove out of the workshop and on to a trailer under its own power. It drove off of the trailer and into its new home shortly after, where it remained untouched until late 2023. 

 

When I began the recommissioning process the car just would not start. By process of elimination I quickly diagnosed a faulty fuel pump. When removed, it was clear why it wasn't happy, it had decomposed into a ball of rust. There must have been some water contamination in the (very small amount) of remaining fuel in the tank that over the 10+ years of storage had created a humid atmosphere in the tank which corroded the pump. 

 

 

The tank also had some damage; some minor damage on the underside / edges from racing where rocks had found a path around the edge of the guard, but more significantly damage to the top near the fuel gauge from an attempted fuel theft when the workshop was broken in to some years before. I managed to find a good used complete tank assembly from a breakers via eBay, gave it a clean up and a paint, swapped it out and the Rav started!

 

The car had not run for very long before it became apparent that the engine itself has some issues. It was very reluctant to start, and when it did it would not idle. It was mid winter by this point, and initially I didn't think anything of the steam when it started but as the time running went on it didn't clear.  There was a misfire at low revs, and a very strange rattling noise on overrun.

 

As the engine is a 3SGE - used in the MR2 of the same vintage - I approached a well know MR2 Specialist in West Sussex for help. After a few discussions over the phone, I ran a compression test and then got the borescope out and was able to ascertain that the head gasket was leaking on one cylinder and that the strange noise was coming from the cambelt flapping around due to a failed tensioner... So the Rav was packed off for surgery.

 

 

The engine had a good check over and replacement head gasket, water pump, thermostat, cambelt, tensioners, belts, oil, filter and coolant change. The idle issue was traced to a faulty coil, which was also replaced along with the plugs, distributor cap and rotor arm. The air filter was also replaced, but this aftermarket item was harder to source as it turned out to have been made by a French company called JR filters. They linked me up with Jetex who were able to import and supply to me.

 

Once the engine work was complete and the Rav was running again OK it was returned and then it was time for MOT. This was passed with flying colours, but after a few days of driving when returning to the car I noticed it started to smell of fuel. Hunting around the car I found evidence of a tiny leak on the return hose to the tank from the engine - there was almost microscopic beading visible in and on the over braiding of the hose only really visible when a torch was shone on it.

 

The hoses were the orginal aeroquip style from when the car was converted and the rubber inners where starting to perrish. The hoses were routed through the car when it was originally built, something that scrutineers are not so keen on these days. With the underbody protection this isnt really needed as the section that was in the car is well clear of impacts and well covered, so I decided to re-route them outside. The hoses were reconstructesd using a mixture of parts from ebay and rallynuts who were extremely helpful sorting out compatible parts.

 

 

Since the recommissioning the Rav has now covered over 500 'shakedown' miles of mixed road and off road driving, so it should have a successful first event!