Wednesday, 10 September 2014

Correcting IVA fail points

The way the test works is they will just test the parts that have failed...or if can make a difference to other areas those as well.

For instance if you had a rear light fail and you moved its position they would check its still within the allowed area.

So how did the test go...well and I came away happy, the tester (Andy) was helpful and thorough, but I did not feel he was there to make me fail. He was there to make sure it was safe and met the requirements. If it didn't he told me what I could do to meet the requirements, or if I wanted to do it another way id ask was it ok. Cant ask for more really!

So on to the fail points, I'm going to list all of them and what I did;

Brake reservoirs lower then highest master cylinder height
So to solve this one was simple in terms of what had to be done, the master cylinders couldnt be moved down as the pedal assembly is welded in position and also the holes for master cylinders drilled. so the reservoirs had to go up. So bracket extensions were made and the reservoirs were raised. they now stick out the bonnet from where I had to cut it. I actually quite like it! Looks a little different and not too over the top! (bodyshop would mesh it properly etc...) Reason this was a failure was because the reservoirs aren't pressurised so really on gravity to feed them when there's a leak

The reservoirs were then meshed for the test as there would be a radius check performed as well.

Steering system has tight spot during lock to lock operaton

This problem needed investigation first and then a fix after. What had happened is one of the unions had too tight of an angle around the 41 -42 degree mark. This was my fault for doing it too tight. So I had to extend one column length and shorten the other to change the angle, the angle is now about 29-30 degrees which is within its operating angle and is smooth to turn.

Fuel pipes in engine bay and breather pipe to be secured, breather pipe also to be fuel grade pipe
I placed rubber round the fuel pipes and cable tied them together so they were secure (the rubber is to protect the pipe from chaffing) and replaced the breather pipe with fuel pipe (marked) and added an additional strap to secure it

Nearside mirror does not meet the field of view requirement
- Also radius incorrect
This was because id left the stalk legs too long so when you looked from the drivers seat you couldnt see the top of the mirror, I removed 50mm off the bottom of the leg and tested it by sitting in the car..hands on steering wheel and looking into the mirror, Also part of the mirror stalk didn't have a 2.5mm radius...a quick mill of it to that radius and that was fixed.

Radius failures on, lower tunnel trim, both door inside rear edges by glass & gear lever surround
Again this was easy to solve, rubber trim was put on to all 3 pieces that failed to give the required radius. the dash lower edge I reheated and turned upwards as well and also placed rubber over it and covered it again.Not pretty but should do the job.

Radius failure on the front bumper
Out came the sandpaper and was sanded to a raduis of 1.5mm. I'm sure ive done enough but if not can be sanded more on the day

Radius failure on top edge of the doors
Because the doors weren't flush with the glass, they needed to have a radius of 2.5mm...out with the sandpaper again.

Wire to prevent rear clam being tilted fully back
Part of the requirements is that when all doors, boots, tailgates etc... are open all lights and reflectors can be seen. It can just be reflectors if there is a warning. So I installed a wire stay to stop the rear clam shell being tilted to far back.

Front indicators not bright enough
Registration lamp not working properly

The front indicators were replace (will have to get some clear lenses I think for them!)

the registration plate lamp played up night before with 2 LED's failing!!! So its been replaced and a spare bought to take with me just in case

Horn symbol on steering wheel when pad does not operate horn

Sanded off and tape placed over it

Vehicle weight exceeded submitted weights

In the UK you submit design weights so they know the vehicle is safe and to work out required braking force, I went over the design weights by around 150kg, they add 75kg per person (so x2) and also includes full tank of fuel. I just need to get an email confirming the chassis / suspension will take this higher weight without any issues

Failed emissions

This was my biggest worry in the first place, first I checked the lamba sensor and couldn't really get it to feed back like required in the test (electronic test) so replaced it, re-performed test and it passed so the lamba may of been playing up.

The car had been idling at 1200rpm which was a bit high anyway.After much diagnosing I decided the ICV (idle Control Valve) was not doing anything at with all the inlet again and testing it. it passed all tests and I could see it working. I then checking loom continuity so all was ok. so the ECU was not controlling it correctly. I decided this was a known issue on the car when I bought it. The give away was the idle screw was screwed in all the way, so I couldn't lower the rpm at idle any more.

To get around the above I set a 12v feed into the ICV and set the ground for it to be always closed, its there to help cold starts anyway (which I wont need), I now turned the idle screw out and got it to idle perfectly at 800RPM. Nice and steady! following this I set up the TPS (throttle position sensor) as it needs to be redone afterwards.

The most exciting bit of this is I have an emissions test on Saturday which I get to drive the car on the road for the first time as well.

That was all of the failures so not too bad really, I'm now waiting of the retest towards the end of the month, so there wont be an update next week and I'm now trying to work out what to do with my time!


  1. Hey James,

    Loving the car and i hope you good luck with your next IVA test.

    I had a couple questions about the DDR kit.
    I've seen people online filing complaints that their kits took too long to come and/or the kits did not come with all parts that were said to be included.

    Did you have any trouble getting your kit?
    How long did it take and did it come with everything?


  2. My kit took about 3 months longer then scheduled and took just under 10 months, however even here in the UK that appears to happen with kit makers. The only bit I didn't get was the fuel tank but I wanted a bigger one made to use original mr2 fuel pump and sender anyway so was always going to have one made..

    My advice would be if abroad and have a high import tax (England works out at 20% tax + duty) Then request a basic kit like chassis, shell. The kit should be a lot less, less import tax, insurance, maybe quicker? So drops the cost a lot. And everything else I looked at could be be bought in the UK so without the added 24.5% on top, hope that helps.

  3. Wow James this has come one loads!
    Must feel good looking at all your hard work - Can I ask what colour are you going for or is it a surprise?
    Keep up the good work!
    PH : swankbaton

  4. Colour is almost decided but a surprise as well as some of the work on the bodywork. The progress has been even better...with a PASS on the IVA today! A good moment although bit further to go yet.