Yesterday I fitted a new throttle cable and then spent several hours in the most uncomfortable position I could find trying to fathom why there was so much slack in the cable... In the end I worked out that the metal "stop" on the back of the pedal mechanism frame was slightly bent and allowing the pedal to return to a resting position further than it should. Managed to get a pair of channel lock pliers to fit on to it after removing the pedal arm completely and bend it back to shape. I was then able to adjust the new throttle cable with minimal slack

happy days

finished the job by adjusting the throttle stop plastic bolt so that it will prevent cable stretch.
Also the protective nipple / cap on the end of the throttle cable is an absolute b**** to remove and reattach so you can slot the cable on to the inlet manifold bracket.
Today I set about investigating the cause of my exhaust fumes issue in the cabin - before anyone makes suggestions I've already done the following -
- Replaced sunroof seals (genuine)
- Replaced rear hatch seal (ebay)
- Resealed tail-lights to body using neoprene gasket
- New hatch lock seal
- Sealed holes in rear cubbies and wheel well with correct grommets
- Sealed any other holes (number plate screws) with gaffer tape
- Replaced bonnet seal (genuine)
I tested the rear hatch seal using a piece of A4 paper at various points around the seal to make sure there was no significant gap when the hatch was closed, I also inspected the edge with a torch whilst the hatch was closed (you can see the seal compressed between the hatch and body). Noticed one small area above the exhaust wasn't compressed as well as the rest so massaged the seal slightly and re-checked fitment.
I then checked the gear stick gaiter and inner boot and found the inner boot has several holes so have ordered a new replacement in case the fumes are coming from the centre tunnel.
I then checked the fitment of the bonnet seal again using a piece of A4 paper to check for any significant gap between the bonnet and the seal.
Then I grabbed my can of Dynax S50 anti-corrosion wax and gave both rear cubbies (battery removed) and the inside of both outer sills a good coating (something I've been meaning to do for ages).
I've added checking / testing / bypass of the catalytic convertor to my list of jobs as I've noticed that the engine bay is very hot after going on a drive (coolant temps stay within the safe region) also wondering if the fumes could be symptoms of cat failure and getting intermittent power loss. That will be a job for the winter possibly as I can also get the following jobs done at the same time -
- Injectors cleaned
- Turbo reconditioned / replaced
