N19

Every so often, as I've been clambering around a Capri in the throes of dismantling, repair and rebuild, over the last 18 months, with yet more being added to the list and no end in sight.... every so often I think to myself, "why am I doing this/ I should have left it as it was!". Then I scroll back to the pictures to remind me of the problems it had hiding below the surface.
 
  
 

I'm due to do a lot of mileage in the Mondeo in the next few months, so I want to make sure that it's going to be ok. Done a few long motorway trips and the temperature gauge doesn't budge, although the heater is on and off, but not as dramatically as it was before (going cold for 10 seconds, before staying toasty warm for the rest of the time). I've been told collection of the Capri for paint in the next 2 weeks.

Every so often, as I've been clambering around a Capri in the throes of dismantling, repair and rebuild, over the last 18 months, with yet more being added to the list and no end in sight.... every so often I think to myself, "why am I doing this/ I should have left it as it was!". Then I scroll back to the pictures to remind me of the problems it had hiding below the surface.
 
  
 

I'm due to do a lot of mileage in the Mondeo in the next few months, so I want to make sure that it's going to be ok. Done a few long motorway trips and the temperature gauge doesn't budge, although the heater is on and off, but not as dramatically as it was before (going cold for 10 seconds, before staying toasty warm for the rest of the time). I've been told collection of the Capri for paint in the next 2 weeks.

I'm due to do a lot of mileage in the Mondeo in the next few months, so I want to make sure that it's going to be ok. Done a few long motorway trips and the temperature gauge doesn't budge, although the heater is on and off, but not as dramatically as it was before (going cold for 10 seconds, before staying toasty warm for the rest of the time). I've been told collection of the Capri for paint in the next 2 weeks.

Slow progress. Reattaching the bonnet is supposed to be a 2 man job, and if the car weren't going for paint soon, I'd definitely have got a second pair of hands doing it!

It's not perfectly aligned by any stretch of the imagination, but as it'll likely have to come off to be sprayed, I'll sort that out further down the line.

With the engine out the car sits nice and noticeably higher at the front!
Meanwhile the wiring loom, bauden cables and so on that go under the bonnet have been wrapped up, hopefully to avoid any damage. Always a little wary with 44 year old wiring, I did worry if it'd cause any issues, but I suppose it's worse if it just floats around under there and invariably gets snagged or whatnot when being moved.

 
Mondeo airlock seems better - did a reasonable bit of driving today and temp gauge sitting reasonably with no wild variation, although the heater was on and off.

I'm due to do a lot of mileage in the Mondeo in the next few months, so I want to make sure that it's going to be ok. Done a few long motorway trips and the temperature gauge doesn't budge, although the heater is on and off, but not as dramatically as it was before (going cold for 10 seconds, before staying toasty warm for the rest of the time). I've been told collection of the Capri for paint in the next 2 weeks.

Slow progress. Reattaching the bonnet is supposed to be a 2 man job, and if the car weren't going for paint soon, I'd definitely have got a second pair of hands doing it!

It's not perfectly aligned by any stretch of the imagination, but as it'll likely have to come off to be sprayed, I'll sort that out further down the line.

With the engine out the car sits nice and noticeably higher at the front!
Meanwhile the wiring loom, bauden cables and so on that go under the bonnet have been wrapped up, hopefully to avoid any damage. Always a little wary with 44 year old wiring, I did worry if it'd cause any issues, but I suppose it's worse if it just floats around under there and invariably gets snagged or whatnot when being moved.

 
Mondeo airlock seems better - did a reasonable bit of driving today and temp gauge sitting reasonably with no wild variation, although the heater was on and off.

Being entirely new to removing engines, and somewhat of a worrier, I'm half convinced that I'm making a massive cockup and it'll never in a million years go back together. But then credit myself with a little confidence that it's all a case of following instructions and being methodical, and even if I do somehow cock it up, I'll learn in putting it right.
Pep talk over, I went through the list from the HBOL...

 
I thought I'd be a smartarse and mark up the propshaft lining up with a chinograph pencil, luckily realised just before taking it off that the grease and so on down here won't guarantee it surviving. I ground a little nick to be sure of having some reference when putting it back together.

The nuts were a bugger to undo with limited ground clearance and a bit of play in the shaft! A spare extension bar was used to stop it rotating, which allowed the nuts to be cracked. A little tugging later and the propshaft slid off.

Also, there's something satisfying about looking at shiny new parts, even if you know that within a few miles it'll be mucky! 

Next job, try to separate the bits of exhaust which really aren't for coming apart... (or, give up, take the angle grinder to the bottom of the manifold, and treat myself to the new manifold as the current one is a bit rusty...)

I remember Volvo B7TLs of that era sounding like a howling vacuum cleaner a couple of years after being new, in the hands of some less well-maintaining operators - shame that they are still groaning around.

Good news. The new exhaust system arrived today and it looks a perfect match. Win.

I have purchased a 1 litre tin of Rust-Oleum paint, matched to the blue paintwork of the Sierra. I must have misheard the man in the shop on Saturday, as I paid £15 for the tin, not £50 as previously suggested.
I have also acquired an engine oil filter.

More parts to come later this week.
 
 

Slow progress. Reattaching the bonnet is supposed to be a 2 man job, and if the car weren't going for paint soon, I'd definitely have got a second pair of hands doing it!

It's not perfectly aligned by any stretch of the imagination, but as it'll likely have to come off to be sprayed, I'll sort that out further down the line.

With the engine out the car sits nice and noticeably higher at the front!
Meanwhile the wiring loom, bauden cables and so on that go under the bonnet have been wrapped up, hopefully to avoid any damage. Always a little wary with 44 year old wiring, I did worry if it'd cause any issues, but I suppose it's worse if it just floats around under there and invariably gets snagged or whatnot when being moved.

 
Mondeo airlock seems better - did a reasonable bit of driving today and temp gauge sitting reasonably with no wild variation, although the heater was on and off.

It's been bastard cold during January and I've been busy and tired, so progress limited.
The Capri turned 44 today! 4 years ago I celebrated the historic status being achieved. I celebrated with a picture on the top of The Spires, complete with a pound shop decoration.


At the time, I had the front seats out and with an upholstorer who did a really really good job with them. I still have the passenger seat, which I picked up from someone in Thetford, it's actually in the car now as I'd worry about damaging the nice originals with so much work ongoing!
End of Jan 2020. How little we knew about how the world was about to go slightly mad.... I still have the banner somewhere. If I keep it for another 6 years, it'll be valid for me!
Back to today.
I did get the brake lines out, including the rear one. It was quite a bugger to release, and I ended up cutting through it so I could get a socket on the rear cylinder. A new full car set is only £55, with all the pipes cut and bent to size. I may also spray them green, which was the original colour.
The hydraulic system was then drained, master cylinder removed, pulled most of the electrical and bauden cables from the front of the car together and secured it. Then got to work on a bit of the surface rust on the engine bay, in a location that would usually be an utter bastard to get to.


Hoping to go away in a couple of weeks and come back for easter.
I changed the coolant on the Mondeo a while ago, and I think I managed to introduce an air lock. The heater varies wildly, as does the indicated temperature and coolant level. I had to pull off the A1 today at South Mymms to top up the expansion tank. Back home, and in the dark, I took off the highest hose in the system (on the rhs of the expansion tank here, next to the water-bottle-funnel) and ran the engine until water started spitting out. See if that behaves any. A little easier solving them on the Capri, massage the big hoses and keep the rad cap off!

The Mondeo also needs 2 new tyres soonish (down to about 3mm). Various long trips in the next few months including Scotland three times, Norwich and Brizzle. 

Slow progress. Reattaching the bonnet is supposed to be a 2 man job, and if the car weren't going for paint soon, I'd definitely have got a second pair of hands doing it!

It's not perfectly aligned by any stretch of the imagination, but as it'll likely have to come off to be sprayed, I'll sort that out further down the line.

With the engine out the car sits nice and noticeably higher at the front!
Meanwhile the wiring loom, bauden cables and so on that go under the bonnet have been wrapped up, hopefully to avoid any damage. Always a little wary with 44 year old wiring, I did worry if it'd cause any issues, but I suppose it's worse if it just floats around under there and invariably gets snagged or whatnot when being moved.

 
Mondeo airlock seems better - did a reasonable bit of driving today and temp gauge sitting reasonably with no wild variation, although the heater was on and off.

Slow progress. Reattaching the bonnet is supposed to be a 2 man job, and if the car weren't going for paint soon, I'd definitely have got a second pair of hands doing it!

It's not perfectly aligned by any stretch of the imagination, but as it'll likely have to come off to be sprayed, I'll sort that out further down the line.

With the engine out the car sits nice and noticeably higher at the front!
Meanwhile the wiring loom, bauden cables and so on that go under the bonnet have been wrapped up, hopefully to avoid any damage. Always a little wary with 44 year old wiring, I did worry if it'd cause any issues, but I suppose it's worse if it just floats around under there and invariably gets snagged or whatnot when being moved.

 
Mondeo airlock seems better - did a reasonable bit of driving today and temp gauge sitting reasonably with no wild variation, although the heater was on and off.

Slow progress. Reattaching the bonnet is supposed to be a 2 man job, and if the car weren't going for paint soon, I'd definitely have got a second pair of hands doing it!

It's not perfectly aligned by any stretch of the imagination, but as it'll likely have to come off to be sprayed, I'll sort that out further down the line.

With the engine out the car sits nice and noticeably higher at the front!
Meanwhile the wiring loom, bauden cables and so on that go under the bonnet have been wrapped up, hopefully to avoid any damage. Always a little wary with 44 year old wiring, I did worry if it'd cause any issues, but I suppose it's worse if it just floats around under there and invariably gets snagged or whatnot when being moved.

 
Mondeo airlock seems better - did a reasonable bit of driving today and temp gauge sitting reasonably with no wild variation, although the heater was on and off.

Engine came out with very little hassle in the end-

Bloody heavy things, a pinto with a gearbox attached. Nicely stowed in the garage for now.

leaving a bereft looking engine bay

Featuring, pile of washing powder over where the gearbox pissed everywhere (just when I thought it was empty!).
Next jobs, removal of o/s wing mirror, clean and degrease the engine bay, remove the brake lines (bar the one to the back - that's a bugger and can stay) and servo/master cylinder.

I forgot to say that in summary, the Sierra is totally solid and doesn't need any further welding. I will deal with the rust proofing and minor cosmetics, then cut and polish the paint and see what I end up with. Hopefully something that is solid and looks presentable. 

Would a pair of these on the front corners be classed as cheating?

Being entirely new to removing engines, and somewhat of a worrier, I'm half convinced that I'm making a massive cockup and it'll never in a million years go back together. But then credit myself with a little confidence that it's all a case of following instructions and being methodical, and even if I do somehow cock it up, I'll learn in putting it right.
Pep talk over, I went through the list from the HBOL...

 
I thought I'd be a smartarse and mark up the propshaft lining up with a chinograph pencil, luckily realised just before taking it off that the grease and so on down here won't guarantee it surviving. I ground a little nick to be sure of having some reference when putting it back together.

The nuts were a bugger to undo with limited ground clearance and a bit of play in the shaft! A spare extension bar was used to stop it rotating, which allowed the nuts to be cracked. A little tugging later and the propshaft slid off.

Also, there's something satisfying about looking at shiny new parts, even if you know that within a few miles it'll be mucky! 

Next job, try to separate the bits of exhaust which really aren't for coming apart... (or, give up, take the angle grinder to the bottom of the manifold, and treat myself to the new manifold as the current one is a bit rusty...)

I've been quiet for quite a bit, a combination of weather, work, and illness.
The wait for paint drags on, I've been pointed towards somebody who has said he can take the car at the end of Jan. We shall see.
After a while discussing engine out vs engine in, I decided it should come out so the bay can be painted too. May as well.
Started by removing the bonnet - a 2 man job, which I managed alone, although I think if it was a finished car with glass in I'd have wanted a second person.

Oil and coolant drained, rad out and all hoses, fuel line off, vacuum, choke and throttle off, battery out, carburettor off...
Lots of random photos taken along the way as reference points of linkages etc, hoses marked up with chinograph pencil.

 

Rest of the fleet - Focus is plodding along quite happily, albeit it is slow on the take-off - whether this is a clutch issue or something I'm not sure, but may need to check and adjust. Mondeo is fine, I did a coolant change and had an air lock I think as we had intermittent heat output and at one point wildly varying temperature gauge - ran the engine parked uphill with the cap off and topped up a bit, seems better now.

Little progress in these parts. Fuel tank was fine, everything nice and tight and running well, gauge works - chucked a couple of gallons of 4* in (at great expense) and it registered (even showing empty on the tank, before taking the old one off, I drained about 2 gallons out).
The old tank itself is still kicking around, I offered it for free online, it's got surface rust but it is intact and perfectly servicable.
Paint wise, I've contacted a couple of other painters that I've had recommended, and one is coming to have a look at the car next week. Hopefully, that will mean some progress!
I'd no idea it'd be quite this long (but I suppose that's the nature of a project like this) and feel a bit silly given that others can work miracles in half the time.
I popped down today for a bit of a tidy up, and to have a looksee at some shiny parts ready for refitting, as some form of motivation. And to figure out the fixing holes for the side rubbing trim which is supposedly a complete cow to get back on! The longer runs have studs along the middle and some sort of clip should be inside for them to locate on. Hmm!

Opportunistic (or magpie-like) as ever, I found an old coat hook board and re-used it as a fan belt storage unit...

Meanwhile, the Mondeo had a further tart up with a couple of coats on the front bumper.

Foam strip arrived and fitted:

 
The back of the speedo had a repair a few years ago - one of the connectors was iffy and I previously soldered some foil to make contact. Maybe need to upgrade - pie tin foil?!
 

 
Mondeo had a wash and a speed-wax this afternoon, which seldom happens.

Slow progress. Reattaching the bonnet is supposed to be a 2 man job, and if the car weren't going for paint soon, I'd definitely have got a second pair of hands doing it!

It's not perfectly aligned by any stretch of the imagination, but as it'll likely have to come off to be sprayed, I'll sort that out further down the line.

With the engine out the car sits nice and noticeably higher at the front!
Meanwhile the wiring loom, bauden cables and so on that go under the bonnet have been wrapped up, hopefully to avoid any damage. Always a little wary with 44 year old wiring, I did worry if it'd cause any issues, but I suppose it's worse if it just floats around under there and invariably gets snagged or whatnot when being moved.

 
Mondeo airlock seems better - did a reasonable bit of driving today and temp gauge sitting reasonably with no wild variation, although the heater was on and off.

Slow progress. Reattaching the bonnet is supposed to be a 2 man job, and if the car weren't going for paint soon, I'd definitely have got a second pair of hands doing it!

It's not perfectly aligned by any stretch of the imagination, but as it'll likely have to come off to be sprayed, I'll sort that out further down the line.

With the engine out the car sits nice and noticeably higher at the front!
Meanwhile the wiring loom, bauden cables and so on that go under the bonnet have been wrapped up, hopefully to avoid any damage. Always a little wary with 44 year old wiring, I did worry if it'd cause any issues, but I suppose it's worse if it just floats around under there and invariably gets snagged or whatnot when being moved.

 
Mondeo airlock seems better - did a reasonable bit of driving today and temp gauge sitting reasonably with no wild variation, although the heater was on and off.