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Author Topic: '91 Capri XR-2 Resto-Mod  (Read 52865 times)

nachius

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    • formerly 91 n/a, now a 91 xr2 being built
Re: '91 Capri XR-2 Resto-Mod
« Reply #345 on: October 31, 2022, 09:32:00 PM »

Gonna be super brief right now, used up literally every spare free second I had.

Talked to Rocketman on the phone for a while today. We got the car cranking with the key! There is a fresh battery and 4 gallons of fresh gas in it. I verified both fuel and spark. Super duper close, guys! It may just be flooded. I'm gonna let it sit for a couple days while I wait for my next few free minutes. Maybe double check all my vacuum hoses and fluids one last time. I didn't expect it to actually crank so soon, there may be stuff I had left un-hooked from testing.

Good news step in the right direction for sure.  I'm excited for it to fire!
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EShepherd

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    • 1991 Capri XR2, 1991 Capri XR2 Rusted out Shell
Re: '91 Capri XR-2 Resto-Mod
« Reply #346 on: November 01, 2022, 04:33:19 AM »

Thanks guys! Won't  have free time until Wednesday, so I'm gonna let it sit until then.

So Matt and I made the big discovery under the cruise control pump thing. In the FL fender, where the chassis harness comes out, there are two four pin white connectors. One goes to the cruise control, and one goes to the transaxle. They are the exact same connector. I, in my infinite wisdom, had the backwards. In other news, I did build a killswitch circuit to bypass the clutch switch. I also finally put a battery in the car!

https://drive.google.com/file/d/1rgBVlmjEWBi31wJKvpA-mMAumrmeR68a/view?usp=sharing - Gauge Cluster
https://drive.google.com/file/d/1sJVSNvufmvhGktjhLjmoOrO7UsP51cS3/view?usp=sharing - Kill Switch
https://drive.google.com/file/d/1sIsHHsVZcbJRvNvAMPJ2FTQyqa9y9mT2/view?usp=sharing - Install Location
https://drive.google.com/file/d/1rxoiAq5NkNXUfe3NuSefxd9JTVGaiUBQ/view?usp=sharing - Engine Bay
https://drive.google.com/file/d/1rqRNIdLiXEsY0m9t4JwnvnjRpkXNjutr/view?usp=sharing - 4 Gallons of 93 Octane (Yay NY)
https://drive.google.com/file/d/1s4hsBX3HMd5z7v6hda03jTCcb56bBUro/view?usp=sharing - DON"T MIX THESE UP!
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greywolf27030

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    • 1991 XR2, 1992 XR2, 1993 XR2
Re: '91 Capri XR-2 Resto-Mod
« Reply #347 on: November 01, 2022, 06:19:08 AM »

cool
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Jack Byrd

EShepherd

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    • 1991 Capri XR2, 1991 Capri XR2 Rusted out Shell
Re: '91 Capri XR-2 Resto-Mod
« Reply #348 on: November 06, 2022, 12:17:04 PM »

Couple things. I suspect my timing is off...so I need to pull the front cover off to get my eyes on the lower mark. Not the end of the world, as I needed to work in that vicinity to replace my alternator anyways. Sit tight, it'll likely take a few weeks worth of days off to get that all apart and inspected. I do know for sure that I have spark, a tach signal, and a functioning fuel pump. All of the ingredients are there, so I think it basically HAS to be the timing that's off.

Anywho, while working on that, I have several other small odds and ends that it's time to tackle. Now that the car has actually decided to have some life. So thing #1, the headlights. It's winter, I live in the north, and so I've been driving both to and from work in the dark. Those headlights are gonna get me killed. Anyone have any recommendations on replacements? The market seems pretty flooded with options. While I'm at it, I'll probably end up sticking LED bulbs in everywhere. I'm also still extremely tempted to buy a set of '94 tail lights....they just look cool. #2- As I was removing my speedometer cable to fill the tranny, it broke. Because of course it did. So rather than deal with hunting down a replacement, my plan was to cap off that hole and install a GPS speedometer somewhere in the dash. That brings us nicely to #'s 3 & 4. The radio/sound system, and the interior in general. I know the radio works, and at least some of the speakers. I really, really want to replace the radio with one of those 90's gems where the screen rolls out and flips up. Ideally with GPS in it. Then the interior, while in decent shape, could use some general TLC. I've toyed with the idea of modifying that "back seat" as it's called, into a spot where I can buckle in my kid's car seat. Sideways, you know, since there is literally zero leg room back there. I think that'd leave a small corner of the back open to stick a small sub & amp. Perfect.

Still unsure if I'm going to try and replace my alternator with the more common unit, or if I'm gonna try and find a local spot that'll rebuild it. Guess I'll decide when I order all the brakes and axles.


Update: Discovered today that in order to replace the front brakes, I'll likely need to disassemble the entire knuckle to get the rotors off. Matt warned me that isn't a very fun job. I dunno how fun 17 year old rotors will be to drive on though. Maybe I'll take a stab at doing the bearings and then do the Galant brake thing at the same time, since I need to replace the calipers anyway.
« Last Edit: November 06, 2022, 04:58:10 PM by EShepherd »
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Rocketman

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Re: '91 Capri XR-2 Resto-Mod
« Reply #349 on: November 06, 2022, 06:36:53 PM »

If you get all the parts needed, bring them down and we can machine the hubs for the Galant upgrade. I have access to a press and also the Ford Special Service tool for checking bearing pre-load. Or just bring OEM bits down, whichever, I have the tools to do them.

I believe the front driverside hub that was on the car when you got it was toast, I think we discussed you swapping on the hubs/knuckles from your white car.

Regarding rear brake calipers, they are getting scarce. I am not aware of any from another vehicle that will work.
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1.8L Turbo All Wheel Drive Capri... the "GTXR2"


EShepherd

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    • 1991 Capri XR2, 1991 Capri XR2 Rusted out Shell
Re: '91 Capri XR-2 Resto-Mod
« Reply #350 on: November 07, 2022, 04:40:03 AM »

If you get all the parts needed, bring them down and we can machine the hubs for the Galant upgrade. I have access to a press and also the Ford Special Service tool for checking bearing pre-load. Or just bring OEM bits down, whichever, I have the tools to do them.

I believe the front driverside hub that was on the car when you got it was toast, I think we discussed you swapping on the hubs/knuckles from your white car.

Regarding rear brake calipers, they are getting scarce. I am not aware of any from another vehicle that will work.

Yes, I replaced the one whole front corner. Can't remember if it was FL or FR. Hopefully I did the right correct corner. Also, after more reading, I think it's most likely I'll just bring you the knuckles and Galant parts one of these weekends. And quite probably try to rent your camshaft locking tool, too.
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greywolf27030

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    • 1991 XR2, 1992 XR2, 1993 XR2
Re: '91 Capri XR-2 Resto-Mod
« Reply #351 on: November 07, 2022, 10:46:55 AM »

The rear calipers interchange with the 323GT and Tracer according to what I've found.
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Jack Byrd

EShepherd

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Re: '91 Capri XR-2 Resto-Mod
« Reply #352 on: November 08, 2022, 04:51:30 AM »

The rear calipers interchange with the 323GT and Tracer according to what I've found.

So there is nothing, as far as replacement rear calipers, for either the Capri or the '89 323 GT. Which year tracer have you heard will work? I'll order a corner and see if it fits. The only other option I think we have available is a few rear caliper re-build kits. Even those are getting scarce, and I'm unsure if they come with more than the square cut seal. Maybe the piston. If it comes down to it, I could do that and replace the bleeders in the rear.

Ideally, someone can figure out a car with a similar enough rear suspension setup that we could start swapping over whole knuckles/struts/etc. Unlikely, but I've been keeping an eye out for it. There's almost no parts available for the rear of the Capri anymore, which is a shame. I think I've only found brake pads/rotors, swaybar endlinks, and strut mounts. That's it.
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greywolf27030

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Re: '91 Capri XR-2 Resto-Mod
« Reply #353 on: November 08, 2022, 04:58:03 AM »

You can take your rear calipers to Advance Auto and have them rebuilt by Cardone.
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Jack Byrd

EShepherd

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Re: '91 Capri XR-2 Resto-Mod
« Reply #354 on: November 12, 2022, 10:21:39 AM »

You can take your rear calipers to Advance Auto and have them rebuilt by Cardone.

For real? I'll have to ask them about this.

In other news, I just ordered the two front axles. I did so because I'm pretty confident I have the intake cam off one tooth. The more I look at it, the more I can convince myself of it. And, aside from the alternator (which I'll be removing to re-do the timing, and hopefully having rebuilt) the axles are the only thing stopping the car from moving under it's own power once it runs. The brakes, wheel bearings, tires, and most of the suspension is somewhere between questionable and alarming, but at least it should be able to move! So the plan is to hopefully tear the front case back apart this weekend while I wait for stuff to show up. Hopefully on Wednesday I can get my alternator to the local rebuilder. Once my fancy shmancy cam timing tool (and new valve cover gasket set) show up, I'll toss the belt on. Beat the old axle stubs out, toss the new axles in. Fill her with trans fluid and figure out some way to plug the hole where to broken speedo cable goes. Pray like hell, then fire her up. If she runs, which she really really should, I'll do the usual heat cycle/oil change on a fresh rebuild. Then start taking her out, see what sort of shape she is in. Ideally I can limp the car to my job, which is about 25 miles from my house. There, I have everything I could need to do the tires, brakes, bearings, suspension, etc. Whatever is ready to fall off the car after all these years.

Edit- Alternator is off the car and with the rebuilder now

Edit2- Timing Pics:
https://drive.google.com/file/d/1ulCqqRN1b2dOI6Gf0gJXaVVezOCW4Xqz/view?usp=sharing
https://drive.google.com/file/d/1urXSmZkM8t0l_9JBefOBuDhaHiBNVz19/view?usp=sharing
https://drive.google.com/file/d/1ulfsz0T7XqWdfuv03rybkuU7spMk2Flh/view?usp=sharing
https://drive.google.com/file/d/1umAozly-LKYlpDNIZVx28k4HCOgQzyD0/view?usp=sharing

So I give up. I can't decide if this looks right and I should leave it alone, or if it looks like the intake came is off a tooth and I should fiddle with it. I've decided to leave it alone and think about it. Does anyone see anything wrong with how this is set up?
« Last Edit: November 12, 2022, 03:04:40 PM by EShepherd »
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EShepherd

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    • 1991 Capri XR2, 1991 Capri XR2 Rusted out Shell
Re: '91 Capri XR-2 Resto-Mod
« Reply #355 on: November 13, 2022, 09:56:00 AM »

Well, I keep flip-flopping on my opinion of if the timing looks right or not. I don't really want to touch it until either I hear from Matt, or I get the tool from FM. Apparently, if I have it timed right, that thing is supposed to just slot right in between the two cam gears. In happy news, I did realize that because I already have the belt on the engine, I won't have to mess with the engine mount if I do need to re-do the timing. So that's nice. It's actually only like a thirty minute process to break the car down to this point and fiddle with it. I am extremely familiar with this engine bay though.

I don't want to waste a day off of work, so I'm trying to figure out other things I could trouble-shoot. I know that with the tach moving, I for sure have both spark and injector pulse. I watched one of the plugs firing. I know all of that is good. I have also heard the fuel pump running. It had about a quarter tank of fresh gas in it. That's all I know on the fuel side, so I figure I'll start there. I want to pull the fuel filter off and order a replacement. While it's off, I'll jumper the fuel pump test connector and make sure I'm getting fuel flow TO the rail. I'm not sure from memory where the return line goes, if anywhere other than from the rail to the tank, but I can make sure I'm seeing good flow through the rail at least. I have no good way to check my injectors, other than a stethoscope while cranking, but that is another possibility.

When I spin the crank around to fiddle with the timing, with the spark plugs in, I feel good compression. I'm fairly confident that's not the issue. The engine went back together with all of it's original parts. I replaced only wear items, and did only the bare minimum machine work. Light decking of the block, and a light polish on the crank. It shouldn't be the issue.

It didn't want to start with starting fluid sprayed into the air filter, either.

Maybe the ECT sensor? I've read that could cause cold start issues.
« Last Edit: November 13, 2022, 10:01:48 AM by EShepherd »
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greywolf27030

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Re: '91 Capri XR-2 Resto-Mod
« Reply #356 on: November 14, 2022, 07:39:33 AM »

Keep up the fight, we're with you.
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Jack Byrd

EShepherd

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    • 1991 Capri XR2, 1991 Capri XR2 Rusted out Shell
Re: '91 Capri XR-2 Resto-Mod
« Reply #357 on: November 16, 2022, 07:08:54 AM »

Keep up the fight, we're with you.

Thanks man! Got a decent little shopping list of parts in over the last few days; fuel filter, I found a speedometer cable replacement, an ECT sensor, a new valve cover gasket set, (I'm a Miata guy, didn't realize that I don't need to take the valve cover off to play with the timing on the Capri. Oops), both front axles (these showed up literally 12 hours after I ordered them), and some axle nuts. Hopefully one of these will do the trick. If not, I'm probably gonna try re-timing it.
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EShepherd

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Re: '91 Capri XR-2 Resto-Mod
« Reply #358 on: November 19, 2022, 05:33:53 PM »

https://drive.google.com/file/d/1wcKoNUgdZMnNbRAGN7PempXjikCYH5qp/view?usp=sharing
https://drive.google.com/file/d/1waEOPr0cOpSmn5fXhSul4AOFvDn_NJoA/view?usp=sharing
https://drive.google.com/file/d/1waBKIifeTs9VxEryjDDLk7hmP2DG7iqk/view?usp=sharing
https://drive.google.com/file/d/1w_HlueTImumCtoGpYvCVziVdC9tDOOse/view?usp=sharing
https://drive.google.com/file/d/1wZTZkyHPK1S1Gpp6GySJr7Be3r82fpkg/view?usp=sharing
 
Orange Auto Electric in Newburgh, NY did a full rebuild on my original 85A Bosch alternator. Guys. This is the same nasty one I gave him, which you can't buy and which you can't buy all the parts for to rebuild. The guy works miracles, and I strongly recommend checking him out if you are local and have any starter/alternator needs.

Tomorrow the car is gonna go back together, and hopefully start.
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greywolf27030

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    • 1991 XR2, 1992 XR2, 1993 XR2
Re: '91 Capri XR-2 Resto-Mod
« Reply #359 on: November 20, 2022, 07:56:44 AM »

I'm lucky enough to have a local guy who can do the same, never even consider buying a rebuilt one.
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Jack Byrd
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