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Old 14th August 2013, 00:24   #1
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Default Rejuvenating a Ford Ikon

You might remember we bought a 10-year old Ford Ikon 1.6 ZXi almost two years back and have enjoyed the overall ownership experience.

Well, the car is owned/used by my bro and he has to make a decision: Sell it off and go for a new one, or restore it back to factory condition.

New car will, obviously, cost more money, and since the Ikon is very much in a running condition why not spend a little bit of money and refurbish it? This is what he discussed with me.

So here it is:

Exteriors:

The car has now completed 13 years of existence. The paintwork has chipped off at places and needs a fresh paint. Recently the car was hit by another vehicle and the right tail lamp has been damaged along with a metal strip which houses the boot lock. Headlights were recently replaced with the clear lens ones. There are no foglamps (we might go for them now). Tyres are about two years old, MRF and have run for less than 10k till now. Wipers need to be replaced. No rust noticed so far on any of the body areas exposed to the naked eye.

Interiors:

Door pads are starting to come off and would probably have to be replaced. Remaining upholstery seems to be good. Seats are good so far, but need to be inspected. Dashboard is good, no rattles, no faded paint. Instrument cluster is good, however the bulb inside is gone. Steering works well, headlight and wiper stalks work good too. Front seats can be pushed/pulled back and forth and could probably do with some greasing of the rails.

The rear power window motors have probably gone kaput and will need to be replaced. Would be a good idea to get all four motors replaced. They have already been serviced once.

There are no abnormal rattles from the car, except maybe the springs.

Drivetrain:

The vehicle has run around 50k kms. The engine is still good (though I personally think it's not as fast as a 1.6 litre should be). There's no smoke, no oil consumption, no abnormal vibrations. Gear shifting is again good, no clutch slippage. No mechanical breakdowns or overheating or any such issues related to the drivetrain.

Suspension:

The entire suspension (minus the coil springs) was replaced around two years back. Though the car scrapes over speedbreakers (which my Nano hasn't done till date), I am thinking it's more to do with the soft nature of the suspension than something else. Though I do feel it odd that the Ikon cannot do what the Nano does. So need advice if this really is due to a softer suspension setup. Also can the suspension be made a little stiffer? What would be the pros and cons?

Steering:

It has power steering and so far it seems to have retained its power.

Electricals:

No major issues, except the dashboard light not working and the indicator blinking/ticking faster than usual (which to my knowledge indicates a short in the circuit somewhere). However I feel it would be a good time to replace the wiring harness.

Airconditioning:

The cooling is really slow. The Ikon's blower at maximum speed (it has 4 speeds) fails to cool as fast as the Nano's blower at the minimum speed. What could be the problem here? We have already checked the gas and that is not a problem. So it's something else.

What we don't want:

No performance tuning is needed. No FFE, no K&N filters. Just want to bring the car back to factory condition.

Now, the budget for all this restoration/refurbishing has to be within 1L max.

Questions:

How do we start? Which areas to tackle first? Are there any parts we should just throw out of the window and replace?

Are parts for the Ikon available in the market?

Any other tips and suggestions are most welcome. I want to treat it like a true restoration project.

I shall try and post some snaps of the car and its underbody by this week-end, so you can get a general idea of its condition.
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Old 14th August 2013, 00:50   #2
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Default re: Rejuvenating a Ford Ikon 1.6L

Speaking as a fellow Ikon owner (Which is also undergoing restoration in stages)- the car is just beautiful. I wouldn't sell it off.

Start with the power windows (so you can go for new trims if need be.)

Replace all fluids (Engine oil, power steering, gear oil, coolant) if they haven't been replaced recently. Then check for transmission and braking issues.

Get the brake discs and liners inspected.

You could probably get the instrument cluster bulbs replaced with LEDs for a lifetime solution (Like my display picture).

This would be a good start to the restoration without putting the car in a garage for days. Then you could take action as required, finishing with a paint job and adding things like fog lamps and visors.

EDIT: I forgot to add, you can also get the power window motors reconditioned- many times it is just a lot of muck on the armature. Possibly you only got the cables greased previously. Also get the window track cleaned and lubricated.

Last edited by RM2488 : 14th August 2013 at 00:58. Reason: Forgot the window motor alternative
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Old 14th August 2013, 01:03   #3
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Default re: Rejuvenating a Ford Ikon 1.6L

The channels are more than 10 years old and I think replacing them might be the best option. Same goes for the window motors, which were serviced already and should be replaced IMO. How about switching to manual winders for the rear windows? They aren't used much anyways.

The brakes and transmission are fine, i.e. no issues so far. The liquids have been replaced two years ago after the car was bought and the oil is being changed every 10k/year with semi synthetic.

The car can be spared, ie. parked in a garage while the work goes on. So while your suggestion is rational, we may want to get all the work done together (since we can't supervise the work always).
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Old 14th August 2013, 01:20   #4
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Default re: Rejuvenating a Ford Ikon 1.6L

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Originally Posted by honeybee View Post
The channels are more than 10 years old and I think replacing them might be the best option. Same goes for the window motors, which were serviced already and should be replaced IMO. How about switching to manual winders for the rear windows? They aren't used much anyways.

The brakes and transmission are fine, i.e. no issues so far. The liquids have been replaced two years ago after the car was bought and the oil is being changed every 10k/year with semi synthetic.

The car can be spared, ie. parked in a garage while the work goes on. So while your suggestion is rational, we may want to get all the work done together (since we can't supervise the work always).
Manual rear windows would be a nice touch. I always fear being trapped in a car with failed power door locks and windows. Breaking the glass can be difficult if you don't know the headrest trick.

You might want to get the A/C coils looked at for the poor cooling. I had that complaint... now works like a charm. I also got rid of the heater.

Also try an ECU scan for pending faults. Best to get all mechanical work done before the paint.
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Old 14th August 2013, 01:38   #5
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Default re: Rejuvenating a Ford Ikon 1.6L

My suggestion is to start with changing all the fluids in the car which includes engine oil, brake oil, gear oil, power steering oil and other if i missed out on any. Than proceed with suspension. As you said you want to take it as true restoration project so i would suggest you to get the entire suspension checked from a good competent mechanic and change all the rubber parts and bushes apart from the parts those need replacement. It will give you trouble free service for many years. For AC work find a good AC specialist and don't depend on multi specialties Garages. Get the compressor, condenser and cooling coil checked and also get the blower unit cleaned, a full AC check up and service in short. After AC proceed with electrical's and get the issues sorted out with power windows. Changing the entire harness is a good idea however it will add substantial amount in the final bill. after after all this is done proceed with painting the car and get the upholstery work done at very last stage of restoration.

All the best for your project.

nIk

Last edited by nik0502 : 14th August 2013 at 01:40.
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Old 15th August 2013, 22:01   #6
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Took the car to the workshop today. The painter says unless something isn't broken, don't fix or replace it. He says the car has been made in a way to last long. The flooring has a layer of coating above and below, sort of sandwiched, to prevent it from rusting. True enough, even though the paint is coming off in places, there's no rust visible anywhere on this 12 year old car.

While driving back we did some back-of-the-envelope calculations. If the On cost 8.5L back in 2000, it would cost around 16L toay, adjusted for inflation!

So now the car will be stripped and each area examined. The mandatory painting, upholstery and such minor work should be complete in under 40k. Will take pics when delivering the car to the garage.
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Old 15th August 2013, 22:55   #7
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Default re: Rejuvenating a Ford Ikon 1.6L

Quote:
Originally Posted by honeybee View Post
Suspension:
Though the car scrapes over speedbreakers (which my Nano hasn't done till date), I am thinking it's more to do with the soft nature of the suspension than something else.
Ikon has a taut suspension, so it is anything but soft. So it doesn't scrape most speed breakers. Kindly check with a qualified mechanic.
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Old 15th August 2013, 23:29   #8
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Default re: Rejuvenating a Ford Ikon 1.6L

Quote:
Originally Posted by honeybee View Post
Took the car to the workshop today. The painter says unless something isn't broken, don't fix or replace it. He says the car has been made in a way to last long. The flooring has a layer of coating above and below, sort of sandwiched, to prevent it from rusting. True enough, even though the paint is coming off in places, there's no rust visible anywhere on this 12 year old car.
.
Exactly my thought. I would just recommend you getting an extra coat so that the car gets that shiny look and u get a feel good factor. Fords are not prone to rusts. My 6 years old fiesta does not show any signs of rusting even when there were two instances when water got inside the car in heavy rains. The level of water was 1 inch above the carpet.

Just get the upholstery done check all the mechanicals so that makes the car more reliable an extra coat on outside and you are good to go. Look forward to your restoration.

nIk
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Old 16th August 2013, 00:03   #9
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Default re: Rejuvenating a Ford Ikon 1.6L

It is a good car which developed a reputation for expensive repairs because of the greedy Ford A$$ people. I know someone who spent 48k just for the suspension work a few years ago. But then, most spares except components can be sourced from the local markets / Opera House.
The painting should be least of your concerns if you want to restore the car for reliable life of 6-7 years. Look at the engine condition which would include the plugs, carbonisation, belts, radiator hoses, bushes, wheel bearings, brakes, clutch, electricals, headlights, tail lights,tyres, battery etc.
Do the painting only when you are done with all this. Also try to get a new floor fabric, seat covers, mats, steering cover, number plates and have the interior fully done at a 3M shop.
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Old 8th December 2013, 23:32   #10
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Default Re: Rejuvenating a Ford Ikon 1.6L

Quote:
Originally Posted by honeybee View Post
area examined. The mandatory painting, upholstery and such minor work should be complete in under 40k. Will take pics when delivering the car to the garage.
Any updates? I was thinking of getting my interiors done, so a couple of pictures would be great.
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Old 8th December 2013, 23:53   #11
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Default Re: Rejuvenating a Ford Ikon 1.6L

The idea of rejuvenating a car is the best idea. I have my doubts on the availability of spares in the long run. I wish, after spending a lakh, you should be in a position to drive the car for few more years. I would also like to draw your attention to the fact that most one time registrations are valid for only 15 years and as your car has already completed 13 years, you may need to extend the registration after that. You should also check the cost of extending the registration for next five years and take that cost also into account when taking a final call on this. I wish you all the best for your project and would wait for the rejuvenated pictures.
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Old 11th December 2013, 09:19   #12
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Default Re: Rejuvenating a Ford Ikon 1.6L

Quote:
Originally Posted by RM2488 View Post
Any updates? I was thinking of getting my interiors done, so a couple of pictures would be great.
Quote:
Originally Posted by mints21 View Post
The idea of rejuvenating a car is the best idea. ... You should also check the cost of extending the registration for next five years and take that cost also into account when taking a final call on this.
At the end, it was simply getting the car repainted - original colour - along with cleaning and polishing of the upholstery. The engine, gearbox - nothing was touched.

After the repaint, the car still didn't perform upto the mark. However the culprit - after a lot of trial and error - was found to be a shorted fuse and a faulty fuel pump. Both were replaced and the car is as good as new now.

The car is currently not at home - I also haven't driven it post the repaint. The next time I get an opportunity for both I shall take pictures - at least of the exteriors - and let you know how it performs.

The mechanic had all along assured us the core mechanicals and electricals were fine and that we shouldn't touch them. I am glad to report his opinion proved to be sound.

Sorry folks, no engine rebuilding or tuning at least for another few years. Also since the car is owned not by me, the owner will take a call on keeping it or selling it. I hope we keep it around for a few more years. We can't possibly recover the amount we have spent on it if we have to sell it.
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Old 29th August 2014, 11:20   #13
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Default Re: Rejuvenating a Ford Ikon 1.6L

After a long break, I got my hands onto the Ikon a few weeks ago. Several issues were noticed, they were obvious as the car had been lying unused for a long time. Fortunately there was no damage caused by rats.

The horns were replaced with Minda Trumpet ones. The right side headlight bulb was replaced. Both the wiper blades were replaced.

I had been hearing a metallic sound from the backside for a few days, which was finally diagnosed to the exhaust end can and part going kaput. Got the end can and exhaust pipe assembly replaced at a local manufacturer of exhaust systems. Now there's no rattle while on the road, and the car doesn't scrape at all on speed breakers. Have to check with heavy load how it behaves on the humps.

The engine doesn't rev easily above 3.5k rpm levels, whereas I am sure my Nano does rev till the 4k mark easily. If the tacho in the Ikon has been marked all the way till 7k, I expect the engine to rev freely at least till about 5k. So what's the cause? Do I really need to open the engine and look inside?
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Old 31st August 2014, 17:27   #14
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Default Re: Rejuvenating a Ford Ikon 1.6L

Hello Honeybee,

You're right. The engine does rev free till 5.5K. There are some immediate checks you can do yourself. I have some questions however.

Is the intake and exhaust modified? Is the air filter clean? Are you sure the local mechanic, when welding the end can, didn't cause any restrictions to exhaust flow by an incorrect weld or something?

Do you see white smoke out of the tail pipe smelling of burnt oil after driving for at least 15 minutes? This indicates scoring on the cylinder walls or worn piston rings.

Get the error codes scanned and rectified if any.

When were the spark plugs last changed? If they're too old, I suggest you change them once. A set of four should cost under Rs. 300.

If you have access to a compression gauge, get the compression checked through the four spark plug holes. It'd be around 9 when new. It should at least be about 8 now.

Only when you're sure there is poor compression you opt to open up the engine. Else it should be rectifiable. Keep that as the last resort.

Do post how it goes.

Regards,
Subramanyam
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Old 8th October 2014, 11:02   #15
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Default Re: Rejuvenating a Ford Ikon 1.6L

Hi Guys,
Can any one of you suggest me a place in Hyderabad, where I can get some of the following done?

- Power Window (currently its manual)
- Change of Door Trim
- Change of Bumpers * Grill (probably something from the newer models or something custom)

I have also seen other threads on Bumpers and other but most of the discussion are focused on Bangalore. Need a good place in Hyderabad. Possibly place to buy second hand parts as well. Cause its becoming very difficult to find parts in Local shops, also service centers are also refusing.

For Engine, I might travel to bangalore, planning for Red Rooster. Please suggest if there is any other cheaper alternatives.

For exterior paint I am planning for New Mars in Kukatpally.. But looks like it will be around 35K or so.. Any other alternatives?

Thanks,
Apratim
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