Bavarian LHD XR2 MK2 - SNOW!!!

[XR2]

This neat blue box was mine for one evening... The threads for the rocker cover screws in the cylinder head were totally fubar... Drilled out the old threads: Tapping new threads: Helicoil ready to insert: Done, as good as new. Or better than:

If you were logged in, you wouldn't be seeing this ad! Register your free account today, or log in if you already have an account.

[XR2]

This is how the engine bay looks at the moment. Just need some new shiny screws and other minor parts. A different air filter box is ordered, inlet and rocker cover are away to get new paint. Still I'm not quite sure about the ignition coils and the HT leads. Want to go back to RSi ones as I've got a mint set with mounting plate lying around. But the red coils won't fit the totally blue/silver engine bay. Also tried BMW or Audi single coils, but they're too short and on the upper side too wide for the CVH head. Might be the late EFI coils with custom made leads or another solution with aftermarket parts...

[XR2]

Got me some stainless steel inhex screws:

left to right:

• throttle linkage bracket
• XR3i ignition coils
• rocker cover and for some parts in the engine bay

These will be for my new custom built doorcards. I'll use rivet nuts and these black inhex screws

[XR2]

got a carbon plate for my RS turbo centre console. I'll put my VDO instruments there

[XR2]

Have been busy today.

I'll sell the RST gearbox, use my short XR3i box again with the later linkage. Probably I'll buy a Quaife LSD while I'm in Great Britain this year to fit into the XR3i box, rebuild it and get a quickshift kit or a linkage out of a Puma.

I always painted my boxes silver. Not long ago I saw a IB5 box painted in black which looked rather cool. So I did my XR3i also in black. But I used satin black and put in some new stainless steel inhex screws after I finished painting it.

[jonny s2]

looking good so far

[XR2]

Got a new pipe for the induction and painted the cover of the MFI air filter box in my new favourite colour: satin black



This was delivered by UPS yesterday, a new bracket for the fuel filter, carbon fibre



Weather is fine, so i painted some more parts. Door cars will be black also, so this will fit fine. Thinking about flocking my spare dashboard...



I'm not the only one with rusty brackets on the seat runners. So i painted them today. Just need to remove the primer on the not painted parts this afternoon.

[Twins]

[XR2]

Tried to fit the Richbrook gear shaft gaiter and the gear shaft sleeve today. I tried but then I found out that the parts Richbrook seels don't fit together properly:



Sent them a not very nice e-mail. I thought I could rely on the quality of parts sold by Burton power which are so expensive and labelled as "Official Ford Licensed Product". Looks now I was wrong. There are at least 2 cm missing so that the gaiter would fit round the sleeve properly. I'm thinking about throwing it all away, with the handbrake gaiter and the handbrake handle. Don't want to spend more time on these parts just to find out they also don't fit!

[AGAR-COSWORTH]

Nice to see some updates on this thread - always enjoyed following your progress.

[XR2]

It's like on the 2000 AC/DC album Stiff Upper Lip:

Can't stand still

I mentioned before I'll change the S1 gearbox for the '87 MFI box I painted in black a few days ago. This means I can use the late linkage again and later a quickshift kit or a Puma linkage. So today I took the linkage apart, ordered some new inner parts @ Ford and painted the selector bar and the mounting bar.



And because the rattle cans and the paint thinner were already open, I painted the cap of the Bailey header tank also. The standard colour didn't match my engine bay and looked like a cheap aftermarket part.



Cleaned also the interior. Not bad for a 25 years old standard drivers seat seen ~ 150.000 km...

[XR2]

And again... did more painting today...




This is gonna be my new ignition setup. I had some Beru Power Cables in blue lying around, used them just for a few months. There are no good looking kits for a 1.6 CVH with EDIS twin coils. Just XR2i ones and they're too long when the engine don't have the EFI type induction pipe.




I'll use the later spec Ford twin coil, bought the right plugs, took a spare cylinder head and tried everything on. Just have to cut the cables now and put them with the connectors into the plugs.

[XR2]

Have been busy the last days...

Made a new bracket for the TPS. Stainless steel.



Some new paint for the inlet and the throttle body



Steering rack with new parts



Late type linkage. New parts inside, fresh paint and stainless screws and nuts outside



Fresh paint for the front tie bars, new screws and nuts also



And the rusty bastard a.k.a. alternator bracket



Carbon fuel filter bracket in position, fuel filter with new fittings



AND FINALLY... after a four years search I didn't expect to get one of these after all... this turned up on ebay for a few Euros. Had some cracks but these are fixed. And I'll use the space inside for a neat installation for the ECU, the fuse box and the fuel pump relay. Some idiot cut out the DIN opening for the radio. So I had to make something individual to close the hole and fit my gauges. Will be finished tomorrow!



Close up



Cables and connectors are in place already, didn't take additional pictures today...

[XR2]

Center console with ECU, wiring and Audi quattro gauges.

[XR2]

Only one picture today:



The manifold didn't look as good as I wanted it to, so I wrapped it in heat protection.

Have done many other things, but they're not worth pictures.

Gearbox is in position, gearbox cradle also with new nuts and washers
Linkage also, already set up
Took the head off, fitted a new gasket and put the head on again
Fitted a new cambelt (hell of a job. Nearly had to take out the engine to get the OT-sensor wheel and the alternator pulley off)
Modified the bracket from the K-Jet for warm-up regulator and auxilary air device for the ISCV
Fitted some new stainless steel jubilee clips
Painted the brackets for the front tie bars and the body shell above them
Finished the wiring loom

[XR2]

Visited Fiesta in the Park today. Some might have seen the two cars with german plates on the xrtwo.com clubstand. The sea grey ST with the white RS-7 most of you might think it's a Zetec-S because of the colour and the 16" wheels.

I arrived savely in Rotherham after a trip north with a guy from www.xrtwo.com, his girlfriend Manda and two of his mates. Was a great experience to visit such an event. It's quite a difference from what We've got here in Germany. But I have to admit... Ater the 100th Focus ST2 I saw, the 300th Fiesta MK5 Sport and the 500th Fiesta MK6 with ST-Look (STs and Zetec S) they get really boring. They all look nearly the same and in most cases there's nothing really special among them. But I enjoyed looking at all the MK1 and MK2 Fiestas at FITP, there are so few left at home in Germany. And there were some other very fine cars, too.

Was nice to meet some of you guys in real life and had a nice talk with some of you.

And I hope the guy from Wales with the broken down car his mate left him with behind also arrives home safely.

Well, now I've got some strange feeling on my mind. When we worked on the welsh XR2 to get it back on the road I heard all those MK2 XR2 drive down to the motorway. This unique sound only 1.6 CVH with a big bore exhaust on full throttle makes. And while these cars were roaring down onto the motorway I imagined what I've missed the last few years.

So I've got a promise for you: As soon as I arrive home from my trip through your country, I'll start work on the XR2 again to get it back onto the road as soon as possible. So that there's at least one XR2 in Germany that keeps the legend alife!

And I've also got a second promise: This was my first visit in Great Britain but sure was not the last. I fell in love with the country a little bit and all the people have been so nice since I arrived in Dover. I can't tell you when this will be at the moment, if it will be with the MK2 and for Ford Fair but I will try to do so.

I hope you all had a nice and safe journey home and I'd like to wish you a good night!

P.S.: Will supply you all with the ~300 photos I made. But the old laptop I've got with me got a little bit nervous because oft the 10 mpix pictures. I'll get that sortet when I'm at home again!

[XR2]

www.XR2.de - FITP pics

[XR2]

Started to prepare the cylinder head. This one's from the XR3i i bought eight years ago. The engine ran 160.000 km and was fine. It's a '87 spec engine, so the valve seats are fine with unleaded fuel. My lambda sensor don't like lead or any other kind of fuel additive.

Today I took off all studs so there's nothing in way for the tools.
And sure - have to take out valves also to do something to the ports.



Custom-made valve spring compressor. But works fine and was free.



I knew that the Irn Bru extreme value pack will be useful some day




The old cylinder head my mate modified six years ago. Will be some kind of an example for me to do the same to the XR3i head






Some kind of bad luck with the old head...




ATM there's a modified RS1600i cylinder head on top of my engine. But this didn't work as good as the old cylinder head and it's for leaded fuel so not really good for my lambda sensor. And exhaust valve on cylinder 2 isn't working properly so it's the right time to change it.

[XR2]

before



after





new head gasket set
and four new outlet valves and chromed rocker cover washers. Had everything in stock, now it's time to use them!



The mechanical work on the ports is done, tomorrow I'll have to use my fingers and lots of sandpaper.
I hope I'll be finished until tomorrow afternoon so I can give the head away for skimming...

[LHD220Turbo]

some top work gone into that car, all the best with the rest of the build - will be awesome once done

credit to you!

[XR2]

Some time ago I bought a new set of ATE front brake calipers for my car. Were quite a bargain.

Was bored yesterday while I waited to get my cylinder head back from skimming. So I decided to prepare them for use when I get my spare front suspension parts back from powder coating.

After a little bit of grinding and sanding I... well... just have a look













































I decided to paint the brake parts of the car in gold colour. The brake pads carriers will follow, the rear drums also. And I think about some braided brake hoses now...

Today I got the head back, nearly finished the ports, just need a little "polish" with ~200 sand paper. I'll finish the head tomorrow (including work on the valve seats), get the XR2 to my father's garage and when there's some time left, I'll take the head off also...

[XR2]

left: new cylinderhead, '87 XR3i MFI, skimmed and ported
right: old cylinder head, '82 RS1600i, round exhaust ports




MFI cylinder head with a set of new RS1600i inlet and exhaust valves, lightweight valve spring retainers and new valve stem seals




Injector sandwich plate mounted. Adapted it to the inlet ports. I tried to get rid of any edges to improve gas flow.
I also put in the camshaft and the rocker cover studs.

[XR2]

Got my new TPS yesterday. The last one did make some problems between 0° and ~25°.

This one's from novotechnik. Works fine. Nearly the same one is sold by Bosch Motorsport. With alloy housing and 3x price!

I'm not happy with the mount but it works.

[XR2]

Well... TÜV until July 2012. Including wheels, tires, steering wheel, exhaust AND injection management!





Didn't have time to wash the ST... Still got Scottish dirt on it. Might try to scratch it off, bottle it and sell it

When you don't know about my trip to Great Britain:

http://passionford.com/forum/general...k-warning.html

[Twins]

Nice scenery in last photo in germany

[LHD220Turbo]

nice one!

car is a credit to you, will last very well with the amount of workmanship you have put in!

all the best

[XR2]

There's always something to do when you own such an old car.

Made new brackets for the RS1600i clocks. Didn't like the old ones and didn't work properly after all...



Did something more, but didn't make pics of that.

Changed the brake fluid sensor for a later type one with a better plug, checked the wiring because the later one also didn't work.
While the left hand part of the wiring loom was opened, I put on a new plug for the fan, because on the old ones cables the isolation was broken and put everything together with a new tape.

Got rid of the MAP with its bracket. I'll go for alpha/n for the next time, so it's just a useless part in my engine bay. Also cut off the plug for the map and the no longer needed cables back. Also used new tape for this part of the injection wiring loom
Changed the ICE. The JVC had such an annoying display with moving pictures. I had an old Sony lying around, but I'll look for a second hand Panasonic one like I've got in the ST.
Took out the Lambda controller. Wasn't working properly so I'll send it to the manufacturer tomorrow.

[XR2]

Decided to give my fuel tank some new paint. Got a new hose from the tank to the pump and an elbow. Don't have to bend a hose anymore. Two broke after a short time... And new stainless screws, nuts and washers to mount the tank. Did you expect anything else?





While the back of the car was in the air, I repainted the rear brake drums. The clear laquer without any primer didn't work. So I used the same paint like I did the front brake calipers that will be fitted to the car in a few days.



The car suffered from massive engine movement. I hope this HD gearbox mounts will cure the problem. Anybody knows in which direction they should be used?

I also ordered a two-component urethane to strengthen the upper engine mount.

[XR2]

A friend of mine starts his own business in Upper Austria today. An official Ford dealer

So I thought about a special present for him. Another friend of mine from Munich also wanted to visit him. We thought about putting a clock into an old Sierra DOHC rocker cover my friend from Munich had lying around. Last week he called me and told me he don't have time to come with me. So he wanted to post me the rocker cover so I can finish it by myself. Until yesterday the cover didn't arrive so I gave him another call and he told me he FORGOT to send the cover. So I had three options: Use my spare RS1600i rocker cover and drill some holes into it, use my old CVH rocker cover that is painted in the cars main colour or ask my local Ford dealer. And... he had a 1.3 CVH rocker cover lying around, in a very good condition and without a mounting bracket for a crossover pipe. And he gave it to me for free. So I cleaned it, closed the part number, sanded it, primed and painted it. And today after a second layer of satin black I screwed the clock and Klaus Ludwigs 24h Nürburgring 1988 polesitter & winner onto the cover.

[PeterRST]

Thank god you didnt waste the 1600i one!

Nice result though.

Will be a familiar sight for him too. The CVH as most people remember it (with the oil cap blown off)

[XR2]

It was an option to use the RSi cover. But not for me.

I thought I had lying lots of them oil caps lying around. The only one that was left sat on my colour coded rocker cover. Didn't want to come off

[XR2]

I'm back home. I had a good time in Austria. Weather was fine, had lots of food and cold beer. And a ride in a Focus RS1 and a black 3-door

http://xr2.bplaced.net/2010poi/index.html

[XR2]

Season is nearly over and I started to prepare the XR2 for the winter months. And because the car was already washed and I didn't take any good photos of the car yet, I had this done today.

[Maxwell]

Hallo!!! Wie gehts dir!?

Your fiesta is super. I love it!! What is your next project? Audi S2?? :P

[XR2]

Thanks. Well, first I'll have to finish the car. Next projects might be children and build/buy a house

[XR2]

Well... took the pictures on Saturday. Wanted to drive around a little bit this week and maybe try some settings for the injection, especially the ISCV that is not connected yet. And now...






I can't drive the car to its dry place for the winter with the summer tires now. And the ST is waiting there, also has got summer tires on with nearly no profile left and the winter tires for the ST are here... quite funny now. At least weather forecast says sun from Wednesday on. Registration plates end at Oct. 31st so I hope the weather gets better soon.

[XR2]

Today I got this back from a friend of mine...

[Part-Box.com]

very tidy motor its a credit to you

[Twins]

So you cant drive out there in the snow without the winter tyres on (against law?) We have winter tyres we put on, as we ski a lot,funny watching people here trying to drive on summer tyres

[XR2]

It's against the law, insurance can refuse to pay and it's not funny to drive. And I've spent so much time and money I don't want to throw it away useless