N19's fleet - exhausting

[sierraman]

They are incredibly straightforward engines, time wise sticking another engine in but have you got the set up to do that and also chances are stuck another clutch in? Personally I’d have the head off and see the damage, if it’s serviceable skim it and belt it back up. 
 

What’s the top end like? Sometimes they rattle like fuck as they get old. If it’s not using oil etc it’s probably good to go again. 

[N19]

I haven't the ability or time to do it myself, so I'd be asking the garage to work on it. Clearly this comes with a cost. Cambelt done 4 years ago and a clutch put on 3 years ago so it's not that it's been undisturbed forever.

I suppose I've nothing to lose.

[N19]

16 minutes ago, sierraman said:

What’s the top end like? Sometimes they rattle like fuck as they get old. If it’s not using oil etc it’s probably good to go again. 

No noticeable oil loss prior to the issue, and no major rattles etc. An odd wandering idle occasionally, but that's it.

[sierraman]

From looking through this thread I think you could do it no problem. Time it up with the locking pins, belt off, exhaust manifold off the front, lift the inlet manifold out the way, from memory release the camshaft top shells in a fashion that releases them gradually, lift the cams out then undo the cylinder head bolts. As engines go these are very basic. 

[grogee]

+1 

I've seen what you've done with the Capri and I reckon pulling the head on the Mondeo will be child's play. 

FWIW I've had the head on and off my Maestro about five times recently and I got the time down to about 4 hours to remove and refit. Admittedly it's an 8v but it is OHC and FWD. 

[N19]

Thanks guys.

I guess it's a confidence thing on my part - not wanting to start having it to bits and then getting stuck, or doing something stupid.

But, as you say, what have I got to lose? The car is effectively un-usable as it stands.

And, I suppose, doing it myself will save quite a bit on labour costs...

[High Jetter]

2 hours ago, N19 said:

Thanks guys.

I guess it's a confidence thing on my part - not wanting to start having it to bits and then getting stuck, or doing something stupid.

But, as you say, what have I got to lose? The car is effectively un-usable as it stands.

And, I suppose, doing it myself will save quite a bit on labour costs...

Also build confidence and widen mechanical knowledge. Plenty of help here from those who know them intimately.

[Surface Rust]

3 hours ago, N19 said:

Thanks guys.

I guess it's a confidence thing on my part - not wanting to start having it to bits and then getting stuck, or doing something stupid.

But, as you say, what have I got to lose? The car is effectively un-usable as it stands.

And, I suppose, doing it myself will save quite a bit on labour costs...

If a ham fisted idiot like me can do a head gasket on a DOHC engine (Saab 900), then anyone can.

Just be methodical. It'll give you a great sense of achievement, after THE FEAR has long since vanished.

[N19]

For various reasons, mainly being swamped with work, I haven't updated this thread in ages.

Mondeo is back on the road. I am afraid to say I chucked most of the work to the garage in the end. Mainly through working long days for most of the last month, and having a deadline of needing the car again. The head was taken off, skimmed, then had new core plugs fitted, reassemble with new cambelt. On re starting, a misfire was found and sorted. I've had it on a few local journeys and probably done about 30 odd miles, it takes a while to build up oil pressure - I'm not sure if they chucked 10W40 in it when reassembling, but that's easily changed.  I have a trip to Scotland in a weeks time, followed by another one a month after that - I'll do a couple of longer round trips this weekend to identify any issues... including a nice long motorway run which is the acid test.

Focus has been in use for absolutely everything, but will now rest a bit!

Finally some Capri progress. It's being picked up and taken to the painter on Monday. Everything has been arranged and at long last things can move forward! I have a period over the next 6 weeks when I'm pretty busy with work and other non-work things, but hopefully it'll come back just as things calm down. And in the meantime I have a few bits to do - the garage needs a good clean and tidy, there's a number of parts to get ordered and picked up and so forth.

[N19]

Also, in honour of the fact I chose to put the money and time into it, rather than any other option, I decided to splash out on a dealer sticker for the rear window. This wasn't the original supplying dealer, but they re-sold it in the early noughties, and Haywards Heath is where I bought it from @garycox four years ago, so it seemed appropriate.

[N19]

Things are moving forward!

Following a few days of local trundling, I decided to test the Mondeo on the motorway. 

I figured that a gentle run at 50-60mph would be wise first, so I popped up to Stevenage, then full speed on the return. Suitable period signage deployed.

 

Arrangements had been made for the car transporter to pick up the Capri, so time to get things ready. The car was pulled out into daylight...

...giving space, whilst waiting for the transporter, for a good wash of the garage floor with de-greaser.  The engine, previously having been down the side, has been moved into the middle (note - moving a pinto with gearbox attached, on your own, is not recommended).

Scuse the terrible picture, but it was taken quite late in the day!

Now wait to see what the painter thinks of it. In the mean time, there are parts to order...

[N19]

When taking the exhaust off I was utterly stuck separating the manifold and centre section, which needed separated to come out. The manifold was in worse nick with some corrosion in quite a few places so I decided to sacrifice that and the angle grinder made light (ish) work of it.

This left the centre section with about 2" of manifold jammed in it.

Picture was after the flanges(?) on the centre section had been opened up, and the whole thing liberally sprayed with penetrating oil. It was not for budging. I got a small flathead screwdriver hammered down the side a few times to allow more penetrating oil to be sprayed in. I carefully cut grooves in the stuck section so that a claw hammer could get some grip and eventually allow some lateral movement. I was then able to use the claw hammer to "scoop" it up slightly (very slowly).

 

Some quite significant time and swearing later.

Centre section "flares" left slightly enlarged for now.

Back section needs rubbing down and a repaint, manifold to be in the next (final? hm not sure) parts order.

I also updated my sad interesting little spreadsheet - 169.5 hours of my time spent on the car since I started stripping it - not counting planning and ordering, discussing jobs, etc.