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Thanks old Tony. It seems to be on the drivers side. I am wondering about the Power steering belt or tensioner. Sounds like a squeal, I will have to get someone to listen to it as I have lost some of my hearing ( Thanks Army). The EGR tube is blocked off. I am going to leave it for a few...

Sorted the gears. Adjusted the clutch pedal, there was a lot more play before the pedal engaged the clutch bearing. Did an ECU reset for the learned fuel usage. Seemed to have fixed the flickering charge lights. I will wait and see. The blower fan not working seems to point to the Risitor...

went into town and had major issues getting gears at stop. Came home adjusted the clutch pedal travel and all good. And now I only have no 4 on fan speed. Another day for that. Leaving the bash plate off for a couple of days to allow for any leaks, but so far all good. Oh and start up the...

It lives. Just took it for a drive and the gear change is a bit stiff, hard to engage. new clutch so I will let that bed in a bit. If anyone can listen and pick anything that I am missing, a rattle? or something. Could be belts? Not sure.

How does it perform? I got this from Ebay as well.

Radiator came here are couple of pics

Does anyone know the torque for the front final drive mount bolts. The bolts indicated by the arrow in the 2 pic. And the front suspension member mounting bolts 2 either end in the first picture. The D40 Thai built manual has them listed as per the pic. Would it be safe to use that torque...

yep I will stay with the 5w. I will update in a couple of days as to how things are going. it's funny you read the manual and think yeah couple of hours to take the engine out. garbage. I still remember taking a 186 out of a HK premier Fuel lines a couple of electrical lines and then the...

On the oil again I wonder if it is worth putting in running in oil first? I don't know. YD25 warranty says synthetic oil only or warranty void. So might stay with that.

Well I bought the oil so I will use that. I have run 15w 40 once and I thought it made the motor noisy especially on start up. My thinking is 5 is thinner so would move through the motor faster on start up. Might change to 10 after the 10k service. but in the end I don't notice a lot of...

Well motor is in, gear box mounted. What a PITA, I had a mate help yesterday to get the motor in on the gear box. Struggled for ages as it is hard to see if you are aligning correctly. After what seemed like hours clunk it went in, got a couple of bolts in and called it quits. Attacked it...

Does anyone know where to get the foam sealing along the top of the radiator and is really required.

I just had a look at another motor in a D22 and my mounting bracket for the Fuel pump is different to my old one. So that bracket is not required.

I had a look at the D40 setup in the manual and it a different setup. No matter I will see what happens when the engine is in and I lay the harness back. it could be a support for that harness. Thanks anyway mate.

Thanks for that. The EGR is blocked off anyway. No reason other than to keep it looking normal. Murphy's law comes into play if I remove it I will get pulled over and get fined. At least it will look normal. YD25 provides a plate to replace the EGR Passage. 19 in the picture. There is...

I am after a favour if someone can take a picture of the Intake Manifold Support Bracket for me. it is No 17 in the picture, I need to know what it does and if anything attaches to it. Been so long and about to put the engine back into the car this week. There is nothing on the old motor that...

Just the clutch and flywheel and it is ready to go back in. Going to give the engine bay a clean first but it should be ready by the end of the week. The fan assy will be taken off. I was checking the space between the alternator mounting bolt and the pulleys. The nut from the factory is at...

Funnily enough when it went I didn't hear the cams break, just engine died and massive loss of power. I didn't know they were snapped until i took the rocker cover off. It will go in this week barring any major setbacks. Taking my time.

That is the carrier bolt, in the first picture you can see the carrier is snapped and the bolt is missing. When the bottom chain snapped the cams stopped rotating but not the crank No 2 cylinder wore the brunt of the meeting of the valves and piston.

One thing I noticed was that there are no torque settings for the rear cover plate and the Timing Signal bolt in the service manual. It has it in the D40 but not the D22 Same motor I suppose FWIW 58.8 nm for the signal bolt and 22nm for cover plate bolts