Daimler Corsica Project - Part 4

...Prior to fitment of the floor carpet...

...that now needed further trimming to fit around the wiring etc.

One aim of the Corsica project was to have all the systems functioning

However, two warning lights refused to extinguish - the bulb fail and traction control. At least with the former there were some lights out that could explain it but for the latter, it was even more bemusing as there was no traction control fitted to the car!

It took some careful reading of the wiring diagrams to establish that the traction control warning was due to a mismatch between a couple of wiring harnesses, fitting matching part numbers cured this.

On the surface, the lighting problem seemed quite simple, some bulbs not fitted or blown maybe? But this was not the case, again it was a problem with wiring harnesses...

...the parts catalogue giving an example of how many different looms there are for the same area of car.

The X300 (mechanically of which this is an example) requires an initial set up when first started. Here the autologic diagnostic system is being used for the first stage...

...and here synchronising the oxygen sensors. Note the use of an old seat. This was to prevent excess wear on the original item during the project

This attention to detail ensured that the exhaust emissions were well within the limit set for this vehicle

The fuel tank was hand made specifically for the Corsica but had not been finished

Mounting brackets needed to be welded to the tank and appropriate pipe work fitted

Before the tank was fitted, elements of the tank breathing and evaporative loss system had to be made and installed

Then there was the minor issue of where to fit all the hydraulic pipe work that had, up until now occupied the aperture where the tank was to go

  

Accommodating all this neatly in the boot was going to be a challenge, the fusebox to the left is for the roof electrics, the one to the right is the main vehicle fuse box

 

The tank installed, viewed from within the aperture that accommodates the roof when folded (the base has been removed for access)

The fuel filler neck had to be made from scratch, using a combination of XJS top filler neck and cap, welded to a pipe with an appropriate curve to meet the tank. As this lower part of the pipe is visible, a chromed item was desirable and after a bit of trial and error, a Series 2 XJ6 exhaust tail pipe was found to be perfect!

All the underfloor brake and fuel lines needed to be cut down to fit the shorter wheel base

This overlap clearly illustrates how much shorter the wheel base is than the standard four door saloon

All the pipes needed to be secured correctly to the floor...

...and the joints in the pipework staggered to prevent "bunching" all in one place

The little details such as the anti chafe bead on the gearbox mount are important otherwise movement could damage the pipes

All pipework and brackets for the fuel filter and suspension units needed to be fitted...

Go to Part 5