Well, i had plans to fire the car up this weekend but discovered some major problems with the braking system

Issue number one: the rear brake pressure reducing valve is clogged which is probably caused when it got anodised/electroplated. I have tried to disconnect it and clean it properly but no luck.

Issue number two: the ABS pump is leaking fluid somewhere from the round motor that sits underneath the valve block.

 

Top work done to a super motor stunning

 

lovely car 10/10

 

Shit Stian, hope it's a easy fix

 

this car seems to be getting better and better top work and a pat on the back to you
shame about the leaks im sure you will sort it out in no time

 

Hope you can fix it mate. Car looks sweet

 

Sorry for the lack of updates but have been working alot to fix those brake issues. Managed to get hold of a good brake pressure reducing valve which fixed one of my problems. Then next problem occured, the T-piece was leaking but had a brand new one so an easy fix. Lessons learned, do NOT anodize/electroplate brake parts.

The ABS pump was leaking from around the motor so i took the whole thing out and used some proper tube sealing gasket. Now it was time to bleed the brakes but by some reason the pump wasn't building up any pressure to the accumulator, no fluid was coming back to the rear calipers either. Took the whole unit out (again) and when opening the motor the small round washer with two tappets only had one tappet left, the other one was broken. With this broken the motor cannot get the other part attached to spin around.

So next task was to source up a new ABS unit and next day i was heading towards a friend of mine to pick up a unit he had laying around. Cleaned it up properly, changed the fluid bottle as mine looked abit better and those bolt and nuts of course. Bolted the new unit into the car and i was ready to bleed the brakes, but the same problem as before occured, the motor was running and running without any sign of building up pressure. I started to get really frustrated now but yesterday i tried to pump the brake pedal without the ABS motor on. The pedal was slowly getting harder and harder, and when i started the motor now it was building up pressure too. After 20-30 seconds the motor stopped, what a relief!

Happy as i was i started to bleed the brakes. Began on the right rear caliper, my assistent pushed the pedal in, started the motor and the fluid came out. Did the same process on the left side with success but when i was close to finish up the right front caliper i heard some dripping from the rear right caliper. It was fucking leaking, and guess what, from inside around the piston!

Now i need to send the calipers back down to Biggred i UK since i got them refurbished there. My plan was to get the car down on it's wheels during weekend but now i need to wait at least 3 weeks

 

Bugger mate

It will be worth the wait

 

Bin them mate there wasted on your car. You can buy brand new genuine Ford calipers from Power torque racing for Ł119

http://cgi.ebay.co.uk/ESCORT-SIERRA-...item5193e2e551



I'm just at the begining of mine, inlet out over the weekend then the engine next

 

Damn that sucks

Good luck with waiting... Times fly when your having fun, but now

 

hope u get it sorted mate

 

it wont be long m8

 

Calipers are now sent back to BiggRed and i will probably pick them up when i'm in UK in August. Flight tickets, rental car and hotel are now booked, really looking forward to Ford Fair

Well, while waiting for the calipers i can sort out some other minor things. Got the gauges connected and wired up here the other day.



I've also ordered a new fuel pump loom as i didn't get the one i bought to work. The new loom will go straight from the battery to the pump and not through the original pump relay.

 

Wow man, really going all out with this, well done! You'll enjoy Ford Fair, plenty of toys to buy for your car and loads of inspiration from the motors on display

 

sweet

 

Oooo very nice

Where can you get the full fuel pump looms from??

I been looking and can only find the ones you refer to, that go through the original relay

 

Gauges look nice mate

 

Ryan on here can make you one

 

Ryan??

Will it be the same qaulity as the other 'kit', with the proper connections on the fuel pump?

 

Cheers mate. Yes, first time at Ford Fair for me this year, definitely gonna use alot of time around the concourse cars to see what the standard are up to

 

It's from an eBay guy called 'gs618328'. The auction has ran out so i had to send him an e-mail.

 

Yeah....their pretty high

 

Good work! Have the same plate in my 4x4.

Ford Fair is great! was there ones. But this year i'm on holliday.

I've also baught a new wiring for the fuel pump. Incl the group a pump. Mine is from ebay and the seller names cw_looms_uk. Fit the wiring also by my brohters 3dr. Verry good! Same as yours, From battery to Pump. Relais in the wiring.

Good luck with it

 

While waiting for the calipers and pump loom to arrive i started working on the boot and spoiler during the weekend. There are some surface rust around one of the mounting pillar that has annoyed me for a long time along with a dent on the boot and some minor paint fault spots on the spoiler.

When disassembling the spoiler only one bolt came out in one piece (of course), both bolt heads for the middle pillar went off and i had to drill off the head on the last one. After some fiddling work the spoiler was finally off and i could start drilling out what was left of the rivnuts in the boot which obviously went easy, but the ones in the spoiler was hard to get out. Now i need to find a couple of new rivnuts to glue back into the spoiler. The two holes in the boot are hexagonal so i need to find some hexagon rivnuts to use there.

The painter is on vacation now so i need to wait a week or two before i can get the boot and spoiler painted. I hope he can only paint and fix those areas where there are some surface rust as i don't want to paint the whole boot since it overall looks very good. Looking forward to get all this sorted out

 

Boot and spoiler are now sent away to the painter.

Have been struggling a bit to get the fuel pump running. The new loom i've got was too short but Gary is a top guy and will send me another one. After a few hours with troubleshooting and pissed off as well i wanted to try the first loom i bought from Prometheus again and then the pump was running. Another problem fixed

Just had to try to turn the engine around for the first time too and it seems like everything is working. So next time, car are fortunately back on it's wheels, fuel on the tank and i'm ready to fire her up.

 

I like the gauges.

 

You''ll get there mate

Also got fuel pump and fan looms from Gary a while ago, good man to deal with

 

Time for a little update again. Bootlid and spoiler are back from painting and got it all mounted today. Think i was really lucky with the painting as i can't see any color difference between the boot and rest of the car. Of course, the boot are more shiny but the car hasn't been washed or polished for the last two years.





Think the boot suits good without any badges but they are coming back soon.



And guess what, wheels are now ordered

 

looking the nuts mate

 

You're for sure a perfectionist when it comes to your Saph!!!

 

looking good mate

 

top work fella its gonna be a cracker once finished

 

What wheels have you ordered mate?

 

Cheers guys

RSRoy: These mate, 8x17" Image DM.

 

diffrent from the rest mate.u not getting old skul comps then?

 

hĺhĺ!
ET???
and price in norske kronur?
(slapp av eg skal ikkje herme)

 

great wheel choice mate

 

Nice wheel but look good at the finish of them. I've red some stories by people who had the same wheels but the quality was lacking initially. Fixed by Image Wheels though

 

Looks good mate, shame you can't drive it yet

How long for the brakes to be solved???