1987 Ford Sierra Sapphire 1.8L - Absolutely fascinating* discovery - see page 48

[Noel Tidybeard]

43 minutes ago, Tenmil Socket said:

ahh if only...😢

[robt100]

Not sure if you will be able to access this, but might also have something to do with the irratic readings if it uses the same method as the Capri tank senders https://www.capripower.co.uk/forum/index.php?threads/fuel-sender-fuel-gauge-operation-problems.43695/

[Peter C]

5 hours ago, robt100 said:

Not sure if you will be able to access this, but might also have something to do with the irratic readings if it uses the same method as the Capri tank senders https://www.capripower.co.uk/forum/index.php?threads/fuel-sender-fuel-gauge-operation-problems.43695/

No access without registration.

[robt100]

Right, wont upload the whole lot. But if you fuel sender is of the same design, it could be the tracks has worn/coroded from sitting for a while. A little bit of use may help, or it might be the wires have been damaged in the resistor unit so it only reads at certain points.

[Morris 63]

Just read through the whole thread over the past couple of days - what a fantastic turnaround from the frustration when you first received it to the lovely state it's in now.

So good to see you being able to get out there and enjoy it. Brings back memories of various pool cars at previous jobs - thrashed to within an inch of their lives round Birmingham's motorways then given back to the (hopefully) unsuspecting manager!

[beko1987]

I had similar on a citroen zx, the fuel needle was jumpy af below 1/4 a tank and the contact points were all worn away. I just got used to 2 1/2 trips to work or 100 miles once it started and filled up! 

Can't hurt to have a mental 'I've got 450 miles if I drive like x or 220 miles if I drive like Y' in your head though regardless of how well the needle works

[Peter C]

I’m gathering parts for the removal and correct reinstatement of the exhaust manifold and downpipe.

eBay has been my friend for the gaskets and exhaust manifold nuts, bolts and washers.

A couple of years ago, I bought this storage unit with all contents at the Enfield Pageant for the grand sum of £1.00

Amongst various treasures, it contains the correct size nuts for the manifold to downpipe joint.

Small win.

I’m so looking forward to grinding the old nuts off. Not.

[sierraman]

5 hours ago, Peter C said:

I’m gathering parts for the removal and correct reinstatement of the exhaust manifold and downpipe.

eBay has been my friend for the gaskets and exhaust manifold nuts, bolts and washers.

A couple of years ago, I bought this storage unit with all contents at the Enfield Pageant for the grand sum of £1.00

Amongst various treasures, it contains the correct size nuts for the manifold to downpipe joint.

Small win.

I’m so looking forward to grinding the old nuts off. Not.

I always keep old nuts/bolts etc, lost count how often I’ve used them! Only last week I was putting a Nissan Juke air box back and the bolt had chewed up, fortunately some old Focus coil pack bolts did the trick! 

[N19]

Enfield Pageant! The last few years it's been on a weekend I can't make, and that includes this year, but hopefully next year..

Old nuts and bolts are always useful and should never be thrown away. Any odd misfits here go into a shortbread tin in the garage (including if I took something out a set, didn't use it, and can't be bothered to work out where it came from)

[Zelandeth]

I do love the instrument panel on the pre facelift Sierras.  With the gigantic legends for the warning lights, not actually where the lights are...really not quite sure what they were thinking with that, but it was definitely distinctive.  Aside from the seatbelt light as I recall...that is actually where the legend is isn't it?

[Peter C]

10 hours ago, sierraman said:

I always keep old nuts/bolts etc, lost count how often I’ve used them! 

Snap.

I do the same. I have a wooden storage unit where I keep all the bits, separated in order, all neat and tidy. That’s where the replacement bolt for the Sierra’s air filter housing came from. However, my stash didn’t contain the right nuts for the downpipe studs and the £1 job lot had to come to the rescue.

[wesacosa]

8 hours ago, Zelandeth said:

I do love the instrument panel on the pre facelift Sierras.  With the gigantic legends for the warning lights, not actually where the lights are...really not quite sure what they were thinking with that, but it was definitely distinctive.  Aside from the seatbelt light as I recall...that is actually where the legend is isn't it?

I remember being really disappointed that the seat belt light didn't illuminate on the facelift ones

[danthecapriman]

2 hours ago, Peter C said:

Snap.

I do the same. I have a wooden storage unit where I keep all the bits, separated in order, all neat and tidy. That’s where the replacement bolt for the Sierra’s air filter housing came from. However, my stash didn’t contain the right nuts for the downpipe studs and the £1 job lot had to come to the rescue.

I’ve always kept old spare nuts, bolts, washers, screws etc etc. you never know when you might need them. Even stuff like plastic clips and blanking plugs.

In my last job I even used to go as far as removing and keeping assorted nuts and bolts from scrap equipment when we raided it for spare parts before it went off to the scrap yard. 
All my colleagues used to wonder why I bothered, but then when they lost a bolt or nut, or something stripped off I was the only one with a tray of replacements! Most of that stuff was old whitworth sizes though so more difficult to buy new.

[riek]

What this really needs is a red, diesel best mate surely?

 

https://www.facebook.com/marketplace/item/2434322780086202/

[Peter C]

17 minutes ago, riek said:

What this really needs is a red, diesel best mate surely?

 

https://www.facebook.com/marketplace/item/2434322780086202/

It looks ok and it’s cheap!

[stuboy]

the 2.3 was a good tow car

[jonathan_dyane]

Wow looks amazing 

[High Jetter]

Red diesel is usually cheaper 😀

[Peter C]

Plan for today was to dismantle the exhaust manifold and downpipe, replace all gaskets and fixings and reassemble the same. 

On this occasion there was no need to lift the car. The hydraulic jack supports the exhaust pipe at the right height. The downpipe to exhaust fixings are easy to reach and came apart easily.

With the air filter housing and a couple of hoses shifted to one side, access to the exhaust manifold couldn't be better.

Last time I removed the exhaust manifold, all eight studs came out with the bolts. On this occasion, one stud didn't fancy coming out, however I managed to persuade it by tightening two nuts together and ongoing the inner one.

The exhaust ports on the cylinder head were a little coked up but there was no evidence of any significant problems.

The new fixings and cylinder head to manifold gaskets came in 7 different plastic bags. Ridiculous. I hate excessive packaging.

I cleaned up the cylinder head and fitted the new studs and gaskets. The new studs screw in with an allen key, nice. 

The mating surfaces on the exhaust manifold looked ok, just a bit of cast iron associated pitting and surface corrosion. 

I clamped the downpipe and exhaust manifold in the vice.

These two nuts didn't look original. 

I thought I'd have a go at undoing them with a couple of 17mm spanners.

No chance! Completely seized solid.

It took me about 45 minutes to carefully grind and file down these two nuts and remove them. 

Unfortunately, the single nut on the other bolt, which looked original, was a nightmare to remove. It took me over an hour to grind and file it along two sides before the bloody thing finally budged. 

Good news is that I manged to get the old nuts off without causing too much damage to the studs.

These are definitely not going into my old spare nuts and bolts container.

First time in 37 years, the exhaust manifold and downpipe are apart.

The gasket was corroded but intact.

I cleaned the mating surfaces of the exhaust manifold and downpipe. There is some pitting but both look ok for re-use.

The replacement gasket was due to arrive today. 

Disappointment promptly followed joy when I saw the postman and found out that he delivered vitamins for my schnauzer and not the new gasket. Bugger. I can do no more until the new gasket arrives.

In other news, I removed the spark plugs to check their condition.

All look good.

Next update soon.

 

 

[lisbon_road]

A chance to drill/wire brush the side of the engine and paint it if you have no wish to enjoy the fine sunshine we have now?

Looks like good progress.  

[Peter C]

16 minutes ago, lisbon_road said:

A chance to drill/wire brush the side of the engine and paint it if you have no wish to enjoy the fine sunshine we have now?

No thank you.

The engine is clean and dry, that's good enough for me.

[Peter C]

New exhaust manifold gasket arrived this afternoon.

Old and new.

Exhaust manifold to downpipe joint now has new gasket, washers and nuts.

Exhaust manifold went back on without any problems.

I refitted all the other bits and tried to start the engine. Nothing, the oil light came on, the ignition light was barely on, as were the dashboard lights (when I turned the lights on). The battery was dead.

I brought out my battery charger to join the party.

After 5 minutes on fast charge, the Pinto fired up.

Not sure what caused the battery to go completely flat. The battery survived the two month lay up whilst I was fiddling with the Sierra and everything performed just fine during last Sunday's outing. 

I let the engine idle for a few minutes. Once warmed up, I could hear a very (and I mean very) slight tick tick tick from the exhaust manifold / top of the downpipe. I'm sure all the nuts are nice and tight. Perhaps there is a small crack in the downpipe somewhere? I will tighten up the exhaust manifold nuts tomorrow.

 

[High Jetter]

1 hour ago, Peter C said:

I could hear a very (and I mean very) slight tick tick tick from the exhaust manifold / top of the downpipe. 

Could just be expansion? Maybe check the nuts tightness when it's cooled.

[tooSavvy]

I had a new front pipe fitted @ATS Wallsend, to my ToMM© Carina II.

It thrubbed and blew, so it went back....

Canny lads, reckoned the clamping studs were karrkedd and set about remedial actions.....

Gas 'to cherry' got the old studs out, new studs in & reclamp + gasket/washers...

About an hour and a half = no charge 👍

To be quite fair, all round, they agreed they shouldn't have attempted the fit... with the studs as raggy... Fair Doos 2 them 😎

🚙💨

[Peter C]

After I fired up the engine via the battery charger on Monday evening, I left the battery to charge overnight. In the morning, the charger battery level light was still only on amber, which I assumed meant that the battery was refusing to receive / hold charge. Time for a new battery. 

Getting hold of the correct replacement battery should have been easy but Euro Car Parts, specifically their website, made the process very complicated and it took me two days to source the correct battery.

I have been advised that the battery that was in the Sierra was not right for the car. Apparently, the battery was more suited to a diesel engine or a much larger capacity pez motor.

I measured the battery.

I also measured the battery tray, which has three holes for the clamp bolt, which means that the battery tray can accommodate different sized batteries. Clever.

Replacement battery purchased and fitted.

The weather forecast for today was dry and sunny so I decided to take the Sierra to work.

I got my surveying kit in the boot.

I drove from home along the M40 and M25 to Old Windsor, then into Windsor, then along the M4 and A404 to Marlow, then to High Wycombe, then back home, approx 65 miles, I think.

The exhaust fumes smell has been fixed. Evidently, exhaust fumes have been getting past the old gaskets / loose manifold and downpipe fixings and replacing the lot has fixed the problem.

On route home I popped into Wickes to buy a fence post.

Which fitted easily inside the cabin.

I have a few more jobs in mind for the Sierra but you will hear about them next week as I have non car related plans for this weekend.

[egg]

I prefer to use Tayna for car batteries now, prices seem fair and when I had to return one because it had gone too flat for my trickle charger, the fees weren't extortionate and process was efficient.

[Conan]

They're completely right 70Ah 620 CCA is wayyy excessive. With cars like these you can get away with almost half that.

[lisbon_road]

I put a giant battery out of a scrappage scheme car in my old Astra for a while.  Lasted to ten years old.  Did wonder what it did for petrol consumption being so heavy but it was free.

Loving this thread and those pictures are great.  Funny really, I remember not liking Smartie blue but now it looks great!

[Peter C]

Any ideas guys?

[bezzabsa]

those pics show how small the sapphire is compared to the moderns - even fits IN a parking space