Getting this 3.0CSi back on the road

[Gransin]

Thank you Gary!

Chris, good point, will cut them before installing :smile:

There has also been some progress with the rear end:

 

[Gransin]

So, I've been busy with buying a house, selling our apartments and moving all the stuff. I've not had any time to put on the car the last month, but my father has been very busy! In fact, the car is back on its own wheels for the first time in a little over 2 years

On to the pictures,

Front subframe back on:

Pedalbox back in:

Grommets in place:

Rolled the car out of the garage and took some better pictures:

Heating unit back in the car:

Brakelines are done, still need to replace the brakebooster.

Fuel-lines, pump and filter done, rear muffler also in place.

I put 215/65-14 tires on my 7x14" ATS wheels, turned out great IMO. Will look much better once the car comes down a bit.

 

[adawil2002]

Wow, everything is so clean and fresh. Except that brake booster, looks like it needs a little love.

 

[Gransin]

Wow, everything is so clean and fresh. Except that brake booster, looks like it needs a little love.

Yeah, I've just bought my thrid brakebooster.. The one that was in the car when I bought it was shot, when I put my foot (slightly was enough) on the brakepedal it slowly applied more and more brake by itself until the pedal was bottomed out. Had to lift the pedal by hand to continue driving.

Bought a second one from Sweden but that one was no good either. Hopefully this third one will be OK, will be painted soon. The one in the picture above is only put there so that the brakelines could be made.

 

[Gransin]

Painted (and hopefully working) brakebooster in place:

Radiator supports mounted:

Handbrake in place and working:

This is the new drainage system that we made, don't know if it is the optimal solution, but way better than letting the water pour down inside the sill..
The hole was made before epoxi base and paint, and the hose is extremely tight around the hole. What do you others think about it, should I put some sealant there or just leave it as is? Consider that this car won't be driven in rain if not caught by surprise.

 

[teahead]

I think that drainage system is a great idea. I think it's silicone around it should be fine to keep water out of the trunk.

 

[adawil2002]

I think that drainage system is a great idea. I think it's silicone around it should be fine to keep water out of the trunk.

Here's a link to Keith Kreegers solution for draining the sunroof into the fender wells. http://www.my2002tii.com/aug2004/index.htm

 

[teahead]

Here's a link to Keith Kreegers solution for draining the sunroof into the fender wells. http://www.my2002tii.com/aug2004/index.htm

I like that idea better (plastic tubing/fittings). Then just use an o-ring on the fittings; won't need caulk.

 

[aearch]

Progress

Have you made any current updates
its very interesting too see

 

[Gransin]

Andrew, thanks for that link!

I've been really busy with moving and getting setteld in the new house, so I can honestly say I've not had much time for anything else. But my father has made progress on the car.

Radiator cleaned, painted and testfitted:

Wipermotor was taken apart and got new brushes, then cleaned and painted. The arms and everything else also refurbished. The axle with splines (where the wiper-arm attaches) still needs some love in this picture and new chrome nuts.

Last but not least, brand new fueltank in place:

Vent-pipe

Put a coat of undercoating on the underside of the tank

That means I have two CSI fueltanks for sale if anyone is interested? One older model tank and one newer model, PM for pictures.

 

[eludvigs]

Wow. Just awesome. Great work!

 

[m_thompson]

Wipermotor was taken apart and got new brushes, then cleaned and painted. The arms and everything else also refurbished. The axle with splines (where the wiper-arm attaches) still needs some love in this picture and new chrome nuts.

I installed a "covering cap" P/N 61611355155 to protect the wiper motor. It is listed as NLA, but maybe you can find one.

 

[FinnCoupe]

I have to ask about the spare-wheel well:

-The wheel securing thing from the middle is still missing?
-The shape of the well, my is smooth, yours have those grooves around?


Excellent work

 

[Gransin]

Thanks for the compliments!

I'll think about the covering cap, but I doubt I'll need that if I'm not going to drive in wet conditions?

About my wheel-well, its a replacement well for a Ford Mondeo Wagon MY -96 to -00. At the time we were replacing the wheel-well there wasn't any reasonably priced e9 replacement wells for sale, cheapest was over 700€ and could not justify that price. I've seen that W&N offers them for under 400€ right now and that's quite annoying but I'll have to try and forget about that. There is no pin in the middle cause I decided not to have a spare wheel in the trunk. Maybe I'm just naive but I've not had one single flat on any of my cars since I got my licence ten years ago, so I just hope my luck continues and If not I'll just have to call someone to go get a spare wheel from my garage.

Merry Christmas to all of you!

 

[Gransin]

There has been a big step forward on the electrical system/harness. I was thinking of going the Autosparks-harness route because it was in terrible shape when it was pulled out of the car. But with many hours spent removing old tape and unnecessary cables, going trough everything with a multimeter and put new tape on it, it's finally back in the car! Not finished yet but it's a very good start.

Lets rewind a bit and look at the pictures of what it looked like after it was pulled out of the car. Looked way worse IRL than in the pictures.

In progress:

And being put back in the car:

Here you can also see that the brakefluid reservoir is in place, and the powersteering oil reservoir-bracket. Fuelhoses in the background.

Speedo-cable in place aswell.

And thanks to sfdon the ignition coil is now resting in the correct bracket.

 

[Bmachine]

Amazing work! Really inspiring.

I imagine that up in Vaasa you probably have 2 or 3 hours of daylight at this time, right? So at least you are not too distracted by others asking you to come and play outdoors...

 

[aearch]

awesome

this is exactly what ive been looking for
EXCELLENT POST THAnKS SO MUCH
as this is what i was wondering as my body
is getting completely redone also
fantastic post i will refer to with great appreciation.
alan

 

[Stan]

Question

Looking at the photos, looks like those "can" relays are plugged into new plastic receptacles. If so, where did you get them? Mine are old and brittle.

 

[Gransin]

Amazing work! Really inspiring.

I imagine that up in Vaasa you probably have 2 or 3 hours of daylight at this time, right? So at least you are not too distracted by others asking you to come and play outdoors...

Thanks for the comment!

We actually have about 5 hours of sunlight, but yeah, it's dark when you go to work and it's dark when you get back home.

this is exactly what ive been looking for
EXCELLENT POST THAnKS SO MUCH
as this is what i was wondering as my body
is getting completely redone also
fantastic post i will refer to with great appreciation.
alan

Thank you Alan!
Would be great to see some pictures of your resto also!

Looking at the photos, looks like those "can" relays are plugged into new plastic receptacles. If so, where did you get them? Mine are old and brittle.

Unfortunately no, I tried to find some new ones but didn't hear anything from anyone.
There were originally three relays in this harness and one of the plastic connector was in bad shape, but as I only need two relays, we just cleaned up the old ones.

But I got a tip from viphoto here on the forum that e3 uses the same plastic connectors if that is any help in search for better ones.


Cheers,

 

[Sven]

This is looking great. After you get the wiring done everything else will seem easy in comparison.

Have you considered adding a third relay for the low-beam headlights while you have the wiring all apart? This is a great safety upgrade and makes for stronger lighting.