Classic cars forum & vehicle restoration.

[Peter_L]

When Bob Dylan recorded this song back in 1963, I was helping my father service his Ford Consul with probably no more than a couple of ring spanners, a large screwdriver and a pair of stillsons that would fit anything larger than 5/8 AF. 50 years on, life under the bonnet is a little different

In the last week or so I have fitted new timing chains, tensioners and a host of new bolts to the engine of my 2002 Ford Explorer.

With little over 150Km (90k miles) the 4.0L V6 should be thought of as just "run in", but the motor industry's fetish with re-inventing the wheel means that this engine has 4 timing chains and more gear wheels than a No 10 Meccano set, plus some ingenious tensioners, guides and other elaborate gizmos. All of which have been modified, improved or eliminated in the years since.

Placing one set of chains at the back of the engine, means the engine has to come out, a task that involves disconnecting over 25 multi connectors that measure a range of important things before sending the data to a computer which will eventually decide if it wants to allow the engine to function.

Of course, one chain guide can't be removed or replaced without taking off the cylinder head and I suppose if I am taking one off I might as well do the valves and what's the point of doing 6 when for twice the work one can do 12.

Back in the day, a bolt was a bolt, give or take a few minor details that one could ignore, not today, now we have torque to yield bolts that have to be replaced, sorry, make that read purchased at a high price and replaced.

Because #6 spark plug can't be replaced with the engine in-situ, unless one removes most of the dashboard so as to get to the bolts that hold part of the air-conditioner which prevents access to the afore mentioned plug, then I will take the course of wisdom and replace all 6 with platinum tipped, nuclear bomb proof super efficient, very expensive things that provide a spark to ignite the petroleum vapour.

Gone are the days of crankshaft pulleys, now we have "harmonic balancers" an ingenious rubber and steel wheel that whizzes around at crankshaft speed and could fail at any time so maybe wise to change it "while we are at it".

Removing this musical delight requires a puller and a special long bolt, because the center of the harmonic is not the end of the crankshaft, so no matter how hard you pull and no matter how many pullers you wreck, that circular contraption will just sit there and laugh.

Nearly ready for the big lift, just use my newly acquired $15 special tool to disconnect the fuel line couplers and forget to tell the authorities that the air con has just evacuated to atmosphere. It needed a re-charge anyway so well worth the $100 to have nice cold air.

So with the engine out, courtesy of a new cherry picker engine lift and an engine balancer beam, it can now be bolted to the new revolving engine stand. It has taken close to 6 hours but the $500 Cnd ( £350) in new garage equipment is less than the labour charge at the garage.

The rest of the dismantling is fairly simple, with just new 0 rings to replace on the injectors, because they are cheap and easier to do now.

Take off the sump, because there could be pieces of plastic from the broken chain guides lurking in the dark corners. We all know they are just waiting to block the oil pick-up as soon as one reaches 80mph on some deserted Interstate.

After all what is a $60 gasket compared with piece of mind.

For a mere $50 there is a valve spring compression tool that reaches to places that normal valve spring compression tools can't even see.

With the heads overhauled and new $80 gaskets and $60's worth of "torque to yield bolts, it is time to fit the new chains, gears and tensioners. Not that difficult really, especially since I am now the proud owner of part # OTC 6488 Cam timing kit. Consisting of 9 well machined and beautifully designed sculptures, it holds, aligns and turns all the important bits so when a piston reaches the top, the valves close and a little spark causes an explosion that send the piston hurtling down the cylinder block.

The good side of this kit is the gorgeous foam lined presentation case and I know that this $260 investment will look really good on the hall table.

All the chains and bits are in place, the $45 Harmonizer refitting tool has done the job and the power unit can be gracefully returned to it's proper home.

Drain and refill the power steering, what's $20 at this stage of the game and it did look dirty, add gallons of coolant, I already had that, so class it as free and may as well start off with Synthetic oil and matching filter.

I know it is another $100 but look at the advantages over ordinary oil.

A quick check at the 10% of connections and couplers that can be seen and crank the engine.

Ignore the "Check Engine" light and watch the oil gauge rise, close the door and engage the seat belt, other wise there is no way of telling what the audible alarm is trying to tell me.

Another check under the bonnet, a quick look on the floor, attach the 26 way multiplug that goes to the ignition box and time for the real thing.

Ignition on, the fuel pump springs into life, didn't hear that before so back out for another look.

OK, now it is show time. The dashboard is lit up like something out of startrek and with a confident turn of the key. "We have ignition"

Uh!! no we don't, try again, "We have ignition". "Nearly, I think"

OK, time to send for "OB1 Kenobi", the $150 super computer that I have had for some time and only used once.

Plug it in, and go for ignition. Codes flash across the screen and settle on PO340 an obvious choice which I should have recognised as a reason for not starting and roughly translated means.

The EEC-V (OBD-2) throws the P0340 concurrently with a P0300, as the engine cannot discern which cylinder misfired, so it blames the camshaft position sensor.

A minor amount of dismantling reveals that the sensor plug is in place and a quick look at the watch reveals it is 20 minutes to closing time, (Parts shop not the Bar) although the latter is now prefered destination.

Vehicle age, model, vin number, engine details, inside leg measurement, are hastily scribbled on to a piece of dirty carboard and thrust into the wife's hand with instructions to call the three parts stores and see who has one of these, another piece of dirty paper with a part #.

As I head down the drive I can hear, "Is this a "B" or "13" ? to which I give the age old repsonse, "don't matter just tell them it's a cam position sensor, they will know what you mean.

I reach the closer of the 3 stores when the cell phone rings.

" Acme Spares" have one, but they close in 5 minutes and the guy is going to his mate's, girlfriend's, brother's party and can't stay"

Of course, age and experience tell me that Acme is the furthest store and even with "blues and two's" flashing it is at least 15 minutes, so it is back home to spend an evening to reflect on times gone by.

A day later and the engine is running. I take that familiar cursory look around for leaks or unwelcomed noises and in my mind I can hear my father say, "if it's obvious it's likely serious".

The frustrations, the skinned knuckles and the blindingly obvious mistakes are forgotten. As for the cost, I refuse to add it all up, what is the point and I haven't even mentioned the $280 it cost for the timing chain kit.


I know that even at local garage prices it would have been a lot more for a lot less and what about that broken piece of plastic, would it still be lurking in some dark corner, ready to pounce and what about the $15 "torque to yield" bolt, how would I know it was changed.

As for the special tools, maybe I will keep them. Just in case...


Fini.

[Bitumen Boy]

Modern cars eh..?

[Rick]

Nice write-up just imagine how much more silly things have become in the intervening 11 years since your car was built!?!

RJ
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[ukdave2002]

I suppose it's the way everything has gone ; old stuff needed frequent simple maintenance ,new stuff very infrequent but more complex....the Peugeot I have just sold requires its first cambelt change at 160,000 miles or 10 years no fun if you like tinkering!!

Dave

[Keith D]

Peter,

Do I detect a note of minor frustration???

I read that with a smile on my face as I am a co-sufferer. I had to pay $50 to buy a workshop manual just so that I could learn how to change a fan belt on a 1999 Mitsubishi Magna! The engine is east-west 3.5 litre Vee six with front wheel drive. The job took well over an hour and I had to remove countless bits just to get in there! The fan belt drives the alternator, power steering pump and air conditioning compressor. (Not the water pump; that's not even visible. That's located in the middle of the engine and is driven by the cam belt!)

I have three plugs (the rear bank) that have to be platinum tips because to change them (and fit their new plug leads) you have to remove the injectors and inlet manifold.

When I was a much younger man, my 1965 Holden was so simple and easy to get at everything, it makes one cry! All this extra rubbish to save a few miles per gallon.

Keith

[JohnDale]

Hi Peter. And so, many good reasons for running classics - excellent write up read with wry smile, & a glad feeling I don't have anything modern,Thanks,JD.
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1958 Ford Zephyr Mk2 Convertible
1976 Ford Granada Ghia.

[PAUL BEAUMONT]

Definitely one thing good about my Jowett! Computer free zone!
Paul

[welshrover]

scrap it and get a proper car .modern junk

[Peter_L]

[Churchill Johnson]

Not only car's i am an agricultural engineer won't mention make but a high price tractor had an air leak from it's air brake's, traced to under the cab so the r/h rear wheel was removed with the aid of a big wheel trolley [wheel and tyre over 6ft high] then cab suspension bolt's removed, cab lifted by forklift 10-12", the fault was a pipe connection which had not been pushed all the way,40yr's ago no cab,air brake's,air conditioning,radio,electronic's, true they could not do 50kph or pull a 16ton grain trailer and 4w/d was a luxury,but my god how easy to work on||.

[ukdave2002]

I do have a beef with modern cars when it comes to headlamp bulbs; manufacturers have made it increasingly difficult to change a simple bulb ...why ?? ok with HD bulbs that are unlikely to fail I can understand, but why do they make it so difficult to change humble halogen bulbs that are a consumable item!!!

Dave

[Keith D]

It is funny how our attitudes change.

I drove cars without air conditioning for donkeys years in our 40 degree summers and did not feel the need for one until after I first sampled one!

I never needed (nor even thought about) power steering or power brakes until after I had driven a car with them!

I still drive my old cars without any of these 'modern' refinements and don't really miss them, but as soon as I get near my 'new' cars I very quickly turn them all on!

Keith

[Bitumen Boy]

[ukdave2002]

I'm with Keith

I've just ordered my new modern,.... and looking at the spec I don't think I actually have to be in the car to drive it

Now in a modern I love all the gadgets, but I wouldn't want any modern gadget on my classics ...a bit like camping I love it, but in the house you want your mod cons

Dave