Mark Seymour - Reference and Resources

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Reference: Ginetta G40 Maintenance Routines & Known Issues

This is my view of when to maintain components of a G40 track car.

Oil changes

  • Approx. every 2,000 - 3,000 miles

Brake fluid

Brake pad and disc change

Spanner check

Check the following in particular:

  • Bolts and brackets holding the alternator
  • Bolts through the wishbones at the front
  • Wires into the alternator and on other side of engine to the starter motor
  • Clips holding the airbox together
  • Exhaust clamps and rubbers  - after the manifold, 1/3 along the side, at the joint by the rear wheel
  • Clips holding the boots on the CV joints at the rear
  • Wheel bolt torque to 80 n/m
  • Oil and other fluid levels
  • Hose clips on the cooling system
  • Hose clips on the fuel line at the syphon valve (on the bulkhead above the pedal box).
  • Mounting bolts holding the differential to the frame (tighten, see bottom of page for picture)

Oil catch tank

  • Empty the oil catch tank after every track day

Air filter

  • Remove and clean with warm, soapy water every six months

Start-up / battery

New Ginetta G40s are supplied with a trickle charger, which plugs into the connector in the boot. See Reference: Ginetta G40 Electrics. Keep connected when the car is stored.

Known weaknesses

  • Exhaust movement (over time, the middle clamp below the passenger door allows movement of the system backwards, into the left-rear tyre)
  • Throttle sticking when engine hot e.g. in traffic - if this happens regularly, check the throttle position sensor (TPS) on the front end of the throttle body / linkage
  • Alternator weakness (bearing breakdown)
  • Alternator upper mounting bolt or bracket breakages. There is a replacement part for this bracket made of nylon.
    Broken alternator top bracket
  • Wiring around the alternator - cable corrosion and breakages, possibly because they are too short or un-sheathed
  • Fuse changes very difficult (old dashboard)
  • Fuel gauge is not accurate
  • Turn indicators stop working - relay comes loose, push back in (new dashboard)
  • Turn indicators stop working at front (fast flash on dashboard) - bulb mounting comes loose in headlight pod
  • Do not use a plug-in 12V compressor for inflating tyres; it will blow a 5A fuse and stop the car starting
  • Brake bleed screw on rear calipers seize up, so don't over-tighten
  • Rear-view mirror falls off, if stored in non-heated garage or in direct sunlight
  • Windscreen will crack easily, as the fit seems to be under a lot of tension and needs a release (caused by gravel strikes on track or even jacking up the car unevenly)
  • Door hinge mountings break down and door drops out of line. The mounting for the lower hinge needs strengthening.
  • Clutch is single-plate and can't take repeated practice starts
  • Starter motor locks after a track session (when hot) or when battery is low (during storage). I'm not sure if this is a solenoid issue or the starter motor itself, but so far, it has resolved itself on my car, by repeated pushing of the start button.
  • Differential mounting bolts come loose (need regular tightening - 10 mm hexagon key to approx 25 n/m)
  • Rear wishbone joints at the wheel side have worn on my G40 after about 5,000 miles.

See also