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XR4i 2.8 12v to 24v auto

Started by Tony, January 05, 2006, 20:10:50

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Tony

wel i have started my conversion on my xr4i to day,,

[attachment=1][attachment=2]

here is the donor car for the engine AND transmision,, yes its going to be automatic !!!!

[attachment=3]
i am going to use all the running gear, brakes etc,, and convert the xr4i to 5 stud so i can use these wheels
(oh i did get 5 off them to)
[attachment=4]
also the zorst is going to go on my xr4x4 as its a noisy one and will not go to well on the xr4i!
[attachment=5]
now this is what is up for grabs if any one is interested,, they are 10 way electric seats, the rears are also available as i am not using them on my xr4i and well the xr4x4 doesnt have interiour at all!
[attachment=7]

many thanks to my friend who braved the cold to help me,, tho he didnt get cold with the thermal overalls!

[attachment=6]

the 24v xr4i auto-0 to 60 in 6.71 secs

Tony

#1
well i had a few hours spent on it today..
[attachment=1][attachment=2]

ow i had a problem with one of the struts, the nut wouldnt turn, to a point the hex rounded off and i was left no option but to cut it off with the angle grinder..
this is no loss ya might think but they where koni ajustables...bugger!

ow well she is now legless
tony


the 24v xr4i auto-0 to 60 in 6.71 secs

Tony

#2
right, just to catch up!
front suspension now fitted, using the granada hubs on to xr4x4 struts!
[attachment=1][attachment=2]
the granny wheels look ok on it BUT
[attachment=3]
the spring mounts hits the tyres, i could change the huge 215/45/17 tyres or change the spring mounts!
any guesses what im going to do?
yup change the spring mounts and keep the big tyres!!

stripped off the front ready for the engine swap and also to see how solid it is...
[attachment=4][attachment=5][attachment=6]
very happy with that!
rear beam was removed from the granada and placed under the xr4i, and

now we are up to to date!.......................

today i bolted the rear beam in correctly, stood the car on the wheels and the camber is really good as it is, tho i expect the back to drop more once the engine and gearbox is fitted!
there was a few issues cropped up, all the gators have split on the drive shafts and (as i expected) the shockers have wider mounts with smaller bolts. easy fix.
other than that the antiroll bar will need some thinking about but later ,,
what do ya think of the wheels on the back?

[attachment=7]

by the way, the springs are chassis dynamics, less 20mm.
the front struts are koni xr4x4 top ajustables and the rear are koni non ajustables!

many thanks mick for the help!
tony

the 24v xr4i auto-0 to 60 in 6.71 secs

Tony

#3

weather is slowing me down right now.. Doh!
but im sure this will soon change now..
but
i have two options with the antiroll bar
option 1
use the xr4i anti roll bar and weld in the outer points to the suspension arms for this..
or
option 2
use the granada anti roll bar and fit this to the xr4i  chassis..

this was easy to figure, it has to be the granada ARB as its huge compared to the xr4i coathanger sized one, also this means i will have ballanced ARB,s as the front one is going to be the 24v one as well

the XR4i ARB mounts are on the outer part of the chassis rail  and are of no use on the new ARB.
The area where the new mounts  should be also has the fuel lines crossing as well.
so inorder to solve this i am making up an adapter to mount to the chassis rail, this will lower the ARB by 3/4" so as to miss the pipes,, more info on this once i have made them...

but research is also going on with the auto box and there are a few tricks in this area that i will employe on my xr4i , tho it will be a standard box at first.

tony

the 24v xr4i auto-0 to 60 in 6.71 secs

Tony

#4
well it didnt rain today, so spent the day removing the engine,,
i think i have found every problem possible tho, bolts rusted in (snapped  a 1/2 snap on rachet)  also then good old anti roll bar brackets had the nut spin on one,, so all in all, up hill battle!
but the engine is now on a trolly  ready to pull out!
[attachment=1][attachment=2]

lets just see how i get on tomorrow!

tony

the 24v xr4i auto-0 to 60 in 6.71 secs

Tony

#5
right been stuck as a "mate"????? has made him self unavailable so i have not been able to use his hoist!
when asked he said i could last friday, i love "mates" like that!
rant over.................................

so we are on plan B!
repared my spare jack and lifted the front up (long process as ya have to go bit by bit)
[attachment=1][attachment=2]
this give me the hight needed to get the engine under the front crossmember (note the dicey use of the axel stands)
the tunnels is just big enough but i am going to have an issue with the mounts i think, but i will see once its in.
[attachment=3][attachment=4][attachment=5]

i also had a look about to see how things where/are after seeing this i figure it would be better to remove the old gearbox mounts but in this case i have gorn to far and hope all misses the ols mounts ok!
ow i did try ti and with the box in the correct position the selector rod just scrapes the old mounts, i can get away with this but if any one is following this, best take the mounts out the way!!
[attachment=6]
and of course all the bloody doughnuts are split, i am looking at a cortina prop shft soon as i think i could use the front section, if i can i can remove the doughnut and have a proppa U/J there. will update later on this..

so my list of parts/jobs has got longer, i now need to...

ajjust the front spring mounts, ether weld some higher up the leg or fit coil-overs
replace the stearing gators both sides!
replace all gators on all drive shafts
mod the back end for the 24v anti roll bar.
new handbrake cable
replace one rear brake as its seazed
change the rear shockers
ow and bleed the brakes
and the doughnut thats split!!!!

the 24v xr4i auto-0 to 60 in 6.71 secs

Tony

#6
right, pulleed me finger out today and with a mate got stuck in!
engine pulled out of the granada

[attachment=1]
then spin round ready to go under the front of the xr4i (yes taps UNDER THE FRONT)
[attachment=2][attachment=3]
then jacked up on two trolly jacks with a scisor jack at the back (no health and saftey stopping me)
[attachment=4][attachment=5]
now with the engine in place the crossmenber was bolted up
[attachment=6]
then she was dropped on all 4's and the bonnet replaced
[attachment=7] [attachment=8]
the wheels look as if they are going to fit rather well, after rolling it back and forwards it seems to have settled, i estimate it will drop anothe 25mm yet tho!
[attachment=9] [attachment=10]

so there we have it,, the 24v xr4i auto is born!
[attachment=11]
a few jobs before its finished off but its basicly done,
ow sorted the tyres rubbing the strut out to, a small mod on the strut and they are done.
brakes,rear ARB and gaters next!

the 24v xr4i auto-0 to 60 in 6.71 secs

Tony

#7
right, got some time today and sorted a small problem.
the granada throttle cable has a nipple at the end and fits in to a key hole on the peddle but the xr4i has a barrel with a clip over it so i wanted to keep the granny throttle and needed to find a way to connect it up!
turned out easy, the peddles are a direct swap,
[attachment=1]
left one is xr4i right one is granny

now at first sight, it looks like there not going to just swap over but they do, the change of the angles matches with the leverage on the throttle so, once swapped over works just fine!!!
[attachment=2]
as you can see this is the auto brake peddle, now,  the peddle box is the same also, how ever the granada one was unpainted and rusty so i swapped the peddle into the xr4i bracket, all works fine to!!
[attachment=3]
here you can see the modded seletor, i found this was to high and got in the way of the cassette rack and radio, so it was stripped down took the light and gear indicator off and the lever was shortend, now i have loads of room and still selects as it should!


tony

the 24v xr4i auto-0 to 60 in 6.71 secs

Tony

right im finaly able to work on the car again
today..
spent some time down the breakers, got odds needed,bumper clips, shocker bolts etc  ,,ow and a pair of xr4i headlamps, at last!!!

fitted the good headlights,, finaly removed the "duck pond look" main beams.. looking better now.

also back end is now in bits, o/s drive shaft gaters are done but broke the t45 torx tool. now due to the farnborough air show i can move till later tonight so couldnt do much more!

making ARB mounts for the rear later tonight ready for the morning

tony

the 24v xr4i auto-0 to 60 in 6.71 secs

Tony

#9
[attachment=1]
well the new headlights look ok, dont you think?

right, hot or not i been baked all day and have made dam good progress
done the other drive shaft gaters, and fitted the brake lines and hand brake cable. so the back end is done bar bleading the brakes and the ARB.
also modded the koni ajustable shockers to fit as well!
[attachment=2]
AND YUP TORQ NUMBER 4 SNAPPED!!
[attachment=3]

ow i also had time to make up the brackets for the anti roll bar to,,
i have taken a simple route here

20mm x 20mm box tube
[attachment=4]
cut a slot around 3 to 4inches in from the edge
[attachment=5]
mark out ready to grind a slot for a bolt
[attachment=6]
now grind two flats on bolts with washers , these have 10mm spanner heads (found in granada's) and you should be able to assemble it like this
[attachment=7][attachment=8]
youl be able to fit a 10mm ring in side to hold the nut
[attachment=9]
cut off and make another
[attachment=10]
there ya go, one set of spacer mounts ready to weld in the rear of my xr4i. ow Note, when fitting remember to put the bolt towards the front as youl never get a spanner on the 10mm head..

i need a beer now!!!!!

gearbox mount tomorrow
tony

[attachment=11]

the 24v xr4i auto-0 to 60 in 6.71 secs

Tony

i did get a bit done yesterday!
removed the unused wires in the loom and retaped the loom,
fitted the rad and made up an oil cooler for the auto box.
the  standard oil cooler was rather hard to fit in so i came up with an idea to use a condensate rad from the air con, this will give me a bigger surface area of cooling and be very eay to fit  in..

this leaves a few jobs for completion

make and fit gearbox mount
fit the propshaft
weld in the antiroll bar mounts at the back
cut&shut the exhaust system
strip the front o/s wheel and replace stearing gater and fit splitpins
plumb in the line-lock and bleed the brakes, ajust hand brake
finish the loom and fit a inhibit switch/reversing light switch
power the loom up and test it,
put some fuel in the petrol tank, check levels etc,
START IT UP!

all going well this is two days work (if all goes well and its not 37 degrees)

i will be MOT'd in the week,,

tony


the 24v xr4i auto-0 to 60 in 6.71 secs

Tony


plumed in the oilcooler today
and
started working on the gearbox mount today, pleased how its working out to..

i am using 20mm x 20mm square tube, to bits 15 1/4 long. i have welded in two ajoining peices and dropped the old xr4i mount in the middle to test the level it leaves the gearbox at..

95mm between the center of the output shaft to the top of the tunnel is what i am aiming for and it turns out to be 98mm but i have not added the flat plate under the mount yet.
now i know this sounds scetchy but i will post pictures soon
tony

the 24v xr4i auto-0 to 60 in 6.71 secs

Tony

#12
right
gearbox mount done, prop fitted and exhaust now modded and fitted,, only electrics and bleeding the brakes to do now..
but
the bloody battery has died!!
soon we shall ride the white xr4i

tony

the 24v xr4i auto-0 to 60 in 6.71 secs

Tony

#13
well i have to say without cossiemk2 i dought if i would have found the errors so fast
but loom is sorted now and yes it runs
it turns out i made 3 errors, 2 off them where small ones, one, 5v feed the engine sensors ooppps eerr will be why it didnt run !

mind, only to get a wet foot the auto box cooler leaked, now swapped for another,,,
hum best fit a speedo, as well !!!!!
brakes now bled through and i have a tidy up and she is ready for the mot,,at last
just got to get on the phone and find some one who can do it now!!!

tony

the 24v xr4i auto-0 to 60 in 6.71 secs

Tony

right
got it in, in the only place that had spaces
(found out why, they fail everything)
however, it failed on....

n/s break low brake effect
horn not working (he refused to put the spade back on)
headlamp aim slightly high (showed him the boot full of tools, still failed it)
n/s suspension component mount rusty  within 18"
o/s suspension component mount rusty within  18"
n/s seat belt anchorage rusty (looks to me like the underseal is pealing off the metal and he says it the floor thats moving but it isnt)
o/s seat belt anchorage rusty (as above)
rear anti roll bar missing (he shouldnt have failed it on this, if it aint there it cant be wrong)
rear break back plates excesive rust (i told him the discs dont have back plates, removed from the his list)
boiled over on the ramps (another wire that was cought with his hand i think )

well i am going to do all this as i feel they are so tuff on cars, if it passes there its got to be better!!!

how ever on the way home the master cylinder started playing up

tony

the 24v xr4i auto-0 to 60 in 6.71 secs

Tony

#15
i converted the dash over to electric speedo (not as easy as ya think)
[attachment=1]
as you might notice, i have carefully un stuck the facia off a cable driven speedo and trimmed it to fit in the front of the surround, then cut the backing on the speedo to fit the hole. but before glueing i had to change the reset on the speedo milometer to fit the front glass..
then it was glued with araldite ,
i have picked up live and earth on the back of the dash so i now only need one signal from the VSS!!

ow and youl notice the revcounter, this is how as i normaly do them
before....
[attachment=2]
and after fitted and running
[attachment=3]

well i looked at the brakes and yeah there was a bit of air in the system but it didnt make to much diferance, the peedle moves a fair bit.
i found this is to do with the standard master cylinder with the granada brakes, its taking more fluid to move the pistons basicly
well as the master cylinder isnt 100% any ways i am going to use the granada ABS master cylinder and pump,, but with no ABS
[attachment=4]
i will start a new thread and post pictures when i start it.. but basicly other that normal MOT issues this project is done. i will be starting a post on the conversion from vacuum servo to ABS type pumped brake master.
this is the only area of concern now as the bigger brakes of the granada requires more fluid to move them that is ideal for the xr4i master cylinder and this gives a soggy feeling on the peddle and tho it works it requires slightly more pressure on the peddle.

tony

the 24v xr4i auto-0 to 60 in 6.71 secs

Tony

I have had to leave this on the back burner for ages, i have had family problems.
after the 18 july i wont have that family to worry about.


ok its been ages, yes but it was MOT'd yesterday and passed.
i have a few small jobs to do but she will be on the road over the next week and back to the workshop in 2 weeks

we are going to remove the gearbox and fit a Hi-Stall converter to get the 0 to 60 times down

but for now she is up and running

ATLAST!

the 24v xr4i auto-0 to 60 in 6.71 secs

TwinTurbo

Did you use the ABS master, did it pass?

TT

Tony

its not on the car yet but it will be and MOT says its ok..

tony

the 24v xr4i auto-0 to 60 in 6.71 secs

TwinTurbo

Cool, I take it you wont have the valve block, just pipes to FR/FL/Rear.. how you going to bias the rears???

TT

Tony

just the electric master cylinder rob, no need to have the valve block unless you add ABS.

we have done some cars all ready, jurgen has converted both his escorts to electric master and they work far better than the old servo types, brake pressure is more progressive and constant


tony

the 24v xr4i auto-0 to 60 in 6.71 secs

cossiemk2

No need to bias the rears.

As the Granny uses the same brake setup as a Sierra with rear discs the balance is OK

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