My childhood dream, Tata Sierra restoration story: Mechanical updates

Started off with the suspension overhaul. The shockers looked in a decent shape and new ones were also not available in the market so decided to change all the bushings only.

BHPian 123.rishabh recently shared this with other enthusiasts:

So updating the thread after 3 months, i will cover the mechanical restoration Part 2 now.

Started off with the suspension overhaul. The shockers looked in a decent shape and new ones were also not available in the market so decided to change all the bushings only. We got all the bushes before starting the work.

It was a very tedious process, since this car has a lot of bushes similar to the old W123 / W124 Mercedes as referred by my mechanic.
This is how it looked without wheels.

While working we found out the front sway bar bushes were not fitting on the vehicle. On further investigation we found that the previous owner had modified the front swaybar to that of the Turbo model (Which was more durable). So reordered them and then changed it.

After the suspension work completion, we planned to change the timing belt cover. I could only procure the Sierra Turbo cover since the standard was not avaiable. It required some precision cutting and alteration to fit it in place.

The old one was just disintegrating and falling apart, we altered and cut the blue encircled part to fit the pulley properly, and the green encircled part was cut and removed to accomodate the auxilary belt. Will be covering the green encircled part later using some custom made plastic part or a rubber cover


Final look for now

Got a new toothed belt also and was installed in place

Coming to the front lights, As i mentioned earlier, the RHS headlamp had some rusting inside but the glass was in a perfect shape. I arranged an aftermarket light and carefully pryed it open in order to use the reflector on my original Stanley Japan Glass. Was time taking but totally worth it.




I forgot to click a final picture after sealing the headlamp.

Also to our surprise, we found a factory fitted Koito Japan bulb inside both headlamps . Also found out the Indicators were still the same that were installed from the factory. Both the side indicators had manufacturing sticker from 1996.
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Apart from this, the radiator has been dismantled and cleaned by an old radiator specialist. Also the Engine and Gearbox mounts have been changed.

The next plan is to do the following
1. Change tappet cover seal & bushes (OE Tata Parts)
2. Change bonnet open cable (Lucky to find OE Telco part)

3. Flush and change the steering Oil
4. Flush & bleed brake oils
5. Check and get the A/C system working.
Hopefully after al this we should be ready for the dent & paint process to start.

Will keep updating as things progress !

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