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Author Topic: '91 Capri XR-2 Resto-Mod  (Read 52854 times)

EShepherd

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    • 1991 Capri XR2, 1991 Capri XR2 Rusted out Shell
Re: '91 Capri XR-2 Resto-Mod
« Reply #390 on: March 20, 2023, 07:15:50 PM »

Parts have started arriving! I'm pretty busy at the moment, so no pictures yet. The rear struts showed up, KYB's. They appear to be correct, too. More stuff is coming tomorrow, and then I'm off on Wednesday. I'm going to try and get it running correctly on that day and then if I have time start pulling the suspension apart to bring to work with me.

As far as getting the thing running right; I've got a new fuel pump (w/in tank filter) & pressure regulator. I'm bringing all the the switches/sensors/etc that are on the passenger side firewall into work to try and superglue new vacuum line fittings onto most of them - they've been damaged and I want to be able to rule any of them out as a cause of my problems. I also think I'm missing a vent solenoid and I forgot to order one...but I can't imagine that's an issue. New rubber lines for the last few ones that haven't been replaced yet. I also have a new starter assembly (mine was quite abused) and a new coolant temperature sensor (been too lazy to install it, but I think it lives by the starter). Then I'll probably use the new fuel pump to push what's left in the gas tank out, and put a few gallons of fresh gash in. Prime the oil pump, then pray for the best. I see no reason it shouldn't stay running at this point; in addition to the previously mentioned, I at some point replaced the ignition coil, plug wires, plugs, fuel filter, air filter, fuel pump relay, dizzy cap & rotor. I know the ignition control module is okay since the tach works. I re-checked the rubber intake boot again just now for cracks and didn't feel anything. New PCV valve & hoses. I also have coolant/oil/timing light on hand to finally (FINALLY) give the engine it's first heat cycle.
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greywolf27030

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    • 1991 XR2, 1992 XR2, 1993 XR2
Re: '91 Capri XR-2 Resto-Mod
« Reply #391 on: March 21, 2023, 08:59:23 AM »

Did you check to see if there is a drain plug in the bottom of the tank?
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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 #392 on: March 22, 2023, 06:02:14 AM »

Did you check to see if there is a drain plug in the bottom of the tank?

So there is a drain plug in the tank. I don't want to be the jackass that snaps off that bolt though, so I pulled the fuel pump out and wedged the fuel filled neck flap open a few days ago. I'm hoping some of it will evaporate, and then I'll just siphon out whatever little bit is left.

The second Carter brand fuel pump I bought, which specifically said it has a 2" outside diameter, is also not correct. It's the exact same size as the 1.5" one I originally purchased. I guess I'll just flow test the OEM one later, and order the damned Delphi unit if needed.
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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 #393 on: March 23, 2023, 06:54:54 AM »

I swear I'll get around to uploading pictures of all the new parts one of these days. I'm waiting on the last couple trucks still, but this pile is growing impressive.

I got a little work done yesterday. I got the old gas out and new gas in; the car does the same thing it did last year. It'll start right up with a little bit of starting fluid, idle poorly for 3-10 seconds, and then stall. If I open the throttle, I can keep it running as long as I want. At this point, I still suspect the fuel pressure regulator. The OEM pump seems perfectly fine, as I used it to push the 4 gallons of old gas out of the tank and it didn't take long at all.

I did not replace the FPR, nor did I replace the starter. The starter is absolutely toast now, and needs multiple attempts to get it to try and start. I didn't feel like laying in the mud to take the thing that far apart, so I didn't. I did manage to patch the exhaust together enough that there is no longer any fear of the neighbors calling the cops on me, so that's nice. I'll continue working on this and hope it fixes the fueling issue.

My attempt at fixing the boost gauge sensor on the firewall failed. Does this send any information to the ECM, or is it purely for the dashboard? Like, do I NEED to replace it?

Likewise, I discovered a single broken wire going to the one pin white connector at the distributor. The wire is broken off/pulled out of the small electrical component that is screwed down to the body of the distributor. What the heck is this thing, and how important is it? I don't see a good way to re-attach the wire, and I can't replace it if I don't know what it is.
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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 #394 on: March 24, 2023, 04:23:28 AM »

https://imgur.com/a/KO3YWqF

First image is the broken boost pressure sensor. Any info on what I can replace this with would be appreciated. I'd like to retain my dash gauge.

Second image is broken wire I discovered going to dizzy. I circled the black thing the wire came out of. I hate sounding so ignorant, but I have no clue what the damned thing is. Halp
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Rocketman

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Re: '91 Capri XR-2 Resto-Mod
« Reply #395 on: March 24, 2023, 03:21:07 PM »

That is the pressure sender for the gauge, the ECU does not read it. The stock gauge isn't the best so I wouldn't fret too much about it. I may have a spare one somewhere, if you come down for bearings we can take a trip to my storage and see what we can find.

The little black box is a RF suppression capacitor, it keeps electrical noise out of the distributor circuit. I have broken them before and run without them, but not a bad idea to have in place though.
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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 #396 on: March 24, 2023, 07:05:38 PM »

That is the pressure sender for the gauge, the ECU does not read it. The stock gauge isn't the best so I wouldn't fret too much about it. I may have a spare one somewhere, if you come down for bearings we can take a trip to my storage and see what we can find.

The little black box is a RF suppression capacitor, it keeps electrical noise out of the distributor circuit. I have broken them before and run without them, but not a bad idea to have in place though.

Thanks for the quick input Matt. I figured it was some sort of noise suppression thingy on the distributor, so I wasn't super worried about that.

Speaking of which, my gigantic pile of bearings just showed up a couple hours ago.

It seems likely that my mystery issue is related to either the FPR or the injectors then. Hopefully it's the one I already have, although I suspect I could clean the injectors while I have the intake off.
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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 #397 on: March 25, 2023, 08:02:28 AM »

https://drive.google.com/file/d/1FUpS6wW5-_dYwo0yT_lFSoVs-ddALTJn/view?usp=sharing
https://drive.google.com/file/d/1rIpG2WMQCaUXoJproJo2X4BbUsMnRGQV/view?usp=sharing
https://drive.google.com/file/d/1Z-paxtOYDWp7gVW9YUfVdjt8Pv_Yz2bI/view?usp=sharing
https://drive.google.com/file/d/1yzrlB-0dM7MbvDteU7vM6Mt8TMmW-_mU/view?usp=sharing
https://drive.google.com/file/d/1lhR958IM_EbTusRENIYQJHIAlnq9iGv4/view?usp=sharing
https://drive.google.com/file/d/12TsGWxJz7cwKBKDX4wPe8rixnZGi_aCc/view?usp=sharing
https://drive.google.com/file/d/1QnBWI5v6j8rJz4qY3v_bfdG41Fx5zhLr/view?usp=sharing
https://drive.google.com/file/d/1BUSWQ0jFBJlGELXt_LjNGhBz8l_KB-BH/view?usp=sharing
https://drive.google.com/file/d/1R-nIvIxfyKFrQrrv-a0FtmTDZCUf2-EL/view?usp=sharing
https://drive.google.com/file/d/1V94jpx_P8kkKSm4plflnPH2XulhKcU3a/view?usp=sharing
https://drive.google.com/file/d/1rAdazLBiAvStZ-3Ht5BuB3TPFJmddihb/view?usp=sharing
https://drive.google.com/file/d/1PerZfTmlTadCyOzzHftEefsiiEHhdOSP/view?usp=sharing
https://drive.google.com/file/d/1X4ZNXx3R3uda5NNYGBW1O2ZnMZs-i3-d/view?usp=sharing

As promised. They get progressively more exciting as you go along. I tried to include all the part numbers, since who knows how much more difficult procurement is going to get as the years go on. The last image is a teaser of my next small project. They are currently my only set, and are in horrible shape. They are destined to be spares, but I still can't have this on my car. Unless someone stops me, I'm leaning towards purple/lilac. Don't forget I do plan to get the car sprayed nardo gray.

I shall attempt to re-build front struts after work today. That factory top mount bolt looks awful funny though....don't wanna have to chop it off.
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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 #398 on: March 26, 2023, 06:56:49 AM »

https://drive.google.com/file/d/1uRdXZT-9p2cVtEuwOG9_34Iwgnhs2Uyd/view?usp=sharing
https://drive.google.com/file/d/1fUGlM29rzzmrMOd5BpHRhjN4krW997_v/view?usp=sharing

So yeah, these things were in even worse shape than they look. In addition to the severe rust and deteriorated rubber, the bearings were also super notchy. You can also fully depress each shock with next to no force, and as you can see they don't have any desire to rebound anymore. I've never actually seen a pair of struts that had so many different failures going on at the same time.


Have a quick little how-to:
1. Mount spring in compressor
https://drive.google.com/file/d/1lmfxKX9jqJrpWGnrIqhPlGSayjPs4itG/view?usp=sharing

2. Compress spring
https://drive.google.com/file/d/1PrU1IUB_cRrT5UV9l0RVMlZtx2FGewTA/view?usp=sharing

3. Remove top nut (24mm open ended wrench)
https://drive.google.com/file/d/1g7ETlR_g7M43KAGa1roR76cZPH_R45sM/view?usp=sharing

4. Persuade stupid nut to let go
https://drive.google.com/file/d/1C2AG0twu5_l_zbo35qpRihkWEftwYLMM/view?usp=sharing
https://drive.google.com/file/d/12ZdihMHZYbGsa8AxYgxztJwcHi1zVhUs/view?usp=sharing
https://drive.google.com/file/d/1FsaGKxZTT1jo2V5uFe2_klODwnWGqX-M/view?usp=sharing
(Caution, hot nuts)

5. Beat the mount and top-hat off with a hammer
https://drive.google.com/file/d/1kizXa3BzdUpqIXkvZWkoLTogurRBCAvw/view?usp=sharing

6. Re-assemble, enjoy
https://drive.google.com/file/d/1hd7Z9oZtaj-Rdh8fKJU6bMf-FtxHJWE1/view?usp=sharing
https://drive.google.com/file/d/1UY51GrbpyQPup5PR1MQUs2Pxe-h6jlv8/view?usp=sharing
https://drive.google.com/file/d/1zh24cJMaRKUgC--ahHJP7HAuTDZTeNa_/view?usp=sharing
https://drive.google.com/file/d/1SzQFNae3xEgy0CrkMrJjVEoWD7_Auxyi/view?usp=sharing


When I eventually get myself a set of H&R springs, I'm going to need to buy new rubber spring seats. The top ones are in okay shape, the bottom ones look like my dog has been playing with them for years.
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greywolf27030

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    • 1991 XR2, 1992 XR2, 1993 XR2
Re: '91 Capri XR-2 Resto-Mod
« Reply #399 on: March 26, 2023, 08:54:08 AM »

Lotta love going on there.
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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 #400 on: March 27, 2023, 07:25:41 AM »

Lotta love going on there.

It's definitely a love/hate relationship. I seem to love her, but I don't think she feels the same way towards me (yet).

I got a good chunk of work done yesterday. The new front struts are on the car, as is the new starter assembly. I had the new fuel pressure regulator on the car as well, and ran the pump for quite a while with some fuel system cleaner in there. It ran slightly better for a little bit, but ended up doing the same thing after a while. I also never got it to start without starting fluid, leading me to strongly suspect I have a leaky injector. I also removed the rear struts, and managed to destroy one of the LR trailing arm bolts in the process. The bushings on the trailing arms are hopelessly rotted anyways, so whatever.

This morning I checked my injectors; I think I found the problem. Of the 4, one of them measured over 14 ohms of resistance. Significantly higher than the other 3, which were all 13.3-13.4 ohms. I then checked, and sure enough that same injector is leaking.

I'm extremely glad that I'm pretty sure I figured out the fueling issue. I think rock auto still has a set of 4 available.
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greywolf27030

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    • 1991 XR2, 1992 XR2, 1993 XR2
Re: '91 Capri XR-2 Resto-Mod
« Reply #401 on: March 27, 2023, 08:25:05 AM »

I'm extremely glad that I'm pretty sure I figured out the fueling issue. I think rock auto still has a set of 4 available.

Good deal.
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Jack Byrd

greywolf27030

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Re: '91 Capri XR-2 Resto-Mod
« Reply #403 on: March 31, 2023, 10:06:57 AM »

Nice....love the gold intake.
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Jack Byrd

EShepherd

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Re: '91 Capri XR-2 Resto-Mod
« Reply #404 on: April 01, 2023, 04:28:14 AM »

Nice....love the gold intake.

Thanks, but in hindsight I sure wish I had just gotten it ceramic coated or something similar. I was making -significantly- less money when I rebuilt the engine, which is a massive shame.

Ah well, at least if I blow it up one day, I won't be too sad when I drop a BP in there instead. Or honestly, I've been low key looking for a well used 4G63 to put into my spare Capri chassis. That car is super gutted, literally just a shell. If I put nothing but a seat and an Evo drivetrain in there, I'm pretty sure I'll need to register for a tail number with the FAA  8)


Gonna have some sweet updates for you guys later on this week; I've got an appointment with Rocketman to learn the lost artform of Capri front knuckle assembly & disassembly. I think we are going to film the process, so hopefully we can take the mystery out of the procedure for everyone. I took my front knuckles to work with me yesterday; only one single technician I work with out of the dozen guys was able to correctly tell me how to take them apart just by looking at them. That guy is also a 62 year old former Ford tech, so in all likelihood he'd probably seen them at some point in his past. What I'm trying to say is - they're really frigging odd.
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