Ferd

Hi All
As you can see I am nearly there And the car dose run.
I have a few small issues and was hoping for a little help.
The first one is there's a small pipe on the right side that comes out of the injector rail and goes to the breather system on the original zetec set up.
I piped it into the Bailey breather by a T piece from the new breather from the block But have found the car will not run.
Not sure were the pipe goes or do I just put a small filter of plumb it into the main air filter.
I am as so having issues with the Bailey dump valve it seems to be opening when I rev the engine think this is done to the spring but I am not sure if I have the right on for the engine.
The other is more of a request for a Zetec ALLOY thermostat Housing so I can machine it to fit the fan switch.

COCHYN

On the breather, you should have a hose from the rocker cover, a hose feeding to the block and the third should either be venting via a small filter or into the induction hose like the Focus RS. If its not idling, I'd suggest checking for any air leaks around the engine as a starting point.

Get rid of the chav valve and have it chatter

Ferd

Right here's a better picture of the breather.
The two top pipes one goes to the rocker the other to the new block breater hole.
The large one, on the bottom has a filter and the small one on the bottom goes to the oil return to the sump.
You can just see the small pipe from the injector rail and the black pipe goes to the T in the pipe from the block.
Was thinking it should go to the small filter some how.
The car runs and idles just fine.

COCHYN

Thought you said the car won't run?

So you have 4 exits on the breather tank then?

Red16

sounds to me like you have piped in the fuel pressure regulator vacuum pipe incorrectly, you got a photo showing which pipe you mean? the hose from the fuel pressure regulator should go to the inlet manifold, so the FPR can see vacuum at idle and boost pressure rising.

as already said, just take it off, much better without

will cost a fortune to have one of those made! what about just T'ing it into the water pump outlet pipework or the pipework which feeds the thermostat from the water pump via the heater matrix. IIRC the zetec themostat housing hold the ecu temp sensor and the dash gauge temp sender.

Ferd

Hi
Yes sorry I did say the car will not run. I should have said will not run with the pipe on.
Other than that she runs fine.

Red16: There are three pipe outlets on the inlet one at the front and two at the rear.
The fuel pressure regulator is piped into the front. The ones at the rear go to the MAP and Dump valve (not connected at the moment)

You can see the small pipe I am on about in the second picture between the breather and coil pack.

Ferd

COCHYN

Stupid question, hoping not to get a stupid answer But you havn't hooked the smaller pipe on the bottom of the breather to the dump valve hose by mistake have you???

Ferd

Hi

NO mate that would be silly. It's going to the sump, Oil return.

Ferd

Jackass1983

little offtpoic:
what ECU do you use?

Cheers Mark

Ferd

Hi
Have a Guess.

Ferd

xrt-mart

iTrader: (1)

The port on the manifold/sandwich plate origialy goes to the intake system via a 1 way valve. This is for emissions to recycle the breather gases. You either need a 1 way valve in the pipe or just block it off. If you do neither then its like having a air leak

As for the dump valve problem. Do you have the small pipe connected to the manifold? After the throttle butterfly. If the pipe isn't connected at all or before the throttle butterfly then the dump valve will just lift under boost conditions. Failing them 2 the valve is faulty.

Hope this helps

Mart

Red16

If its the pipe i've arrowed in the pics below you are talking about...



that pipe is a vacuum pipe take off, its coming from the injector sandwich plate not from the injector/fuel rail, you could be connect a dump valve, map sensor, actuator, boost gauge etc to it, if youre not going to use it just blank it off.

pa_sjo

It's not a vacuum take-off, it's part of the breather system. It usually goes to the breather on the front of the block via a PCV valve.

Red16

what is a PCV valve?

regardless of how it was used before in the photo of his engine it is working exactly like a vacuum pipe, the pipe is connected internally to all 4 inlet ports... so it would be seeing exactly the same vacuum/boost as the other take off pipes he mentioned that are in the manifold.

sexr3i

Yeah that pipe is open to all 4 ports. Just stick a bolt in it.

JesseT

You're are letting air in from the pipe in the injector block that is confusing your ecu. Just block it if you don't need to recirculate your breather fumes for legal reasons.

Ferd

Hi All

Yes that’s the pipe and I knew were it was from.
I do not think blocking it off is an option as the engine just dies then I put my finger over it.
Would be interesting to find out what would happen if I did that to a normal Zetec.
I will go over the breakers Monday and get the right pipe and try it.

As for the pipe on the top of the inlet it’s going to the FSE at the moment but I will be having a play with the pipes.

Ferd

pa_sjo

The chances are the ECU you're running (assuming it's not mapped, or is on a base map of some kind) is happier at the wrong MAP reading causes by the vacuum leak and when you correct the vacuum reading by blocking the leak, it runs too poor and cuts out.

Ferd

Thats a vey good point.
And come to think of it it's a Megasquirt 2 ECU and it is on a base map. Your just to good. I will have a look later.

Ferd

sexr3i

I put a bolt in mine and mine runs on a megasquirt basemap.

Ferd

Hi
I connected the pipe up to a T in the block breather and found the MS was fuelling at 10msec so I changed that to 5msec and she ticks over very well but finds it hard to Rev.
I think that’s down to the acceleration enrichment table.
Will have a read and have a play later.
I have put a Lamba in my system so I will be setting up the self tune soon.

Sexr3i Can you send me your base map so I can have a look.

ferd@ic24.net

Ferd

pa_sjo

What's the spec of the engine/turbo/injectors?

JesseT

Just block it unless you wont to burn oil in your cylinders. If it dies, you will need to increase idle speed to compensate.

RSturboJET

That pipe should be blocked off. It's used to suck breather fumes into the engine under vaccum and is regulated by a pcv valve. Since it'a zetec turbo it's only going to blow air into your breather and you'll loose a lot of boost. If you leave it, it'll cause backfires and a load of other problems. The reason it's only running with the pipe unconnected is probably because it's mapped too rich and/or the idle speed isn't high enough.

Vampire

on a normal zetec engine if that pipe is not connected and left open it stals the car as the pressure from your inlet escapes. if you r not running a 1 way valve into that pipe in the inlet, then block it off!!!

TimB

If your using a megasquirt you could try using one of the spare outputs to control the fan relay and bin the switch.

have a look at http://www.megamanual.com/ms2/spare.htm

HIGHTOWERescort

Shouldn't your filter be at the top of your breather pot, not the bottom?

Any oil going into there now will be trying to vent upwards, and having the filter at the bottom will lead to oil leaking out of it?

pa_sjo

Go look in a breather pot or catch-can

HIGHTOWERescort

Please can you explain what you mean? What should I be looking for?

Please note I ended what I said with question marks? It was a genuine query, I don't want to seem a smart arse, but I do want information, as I have a catch tank with the filter at the top, as that seems logical to me? The fumes rise, while the fluid drops?

My catch tank does not have a drain on it, though? Is this where the difference lies?

pa_sjo

This photo may assist your discovery: http://www.autoxcooper.com/images/cr..._catch_can.jpg

HIGHTOWERescort

That looks like one of them computer water cooling thingy-me-bobs

What bit should I be looking at?

How should I be plumbing a catch tank? Mine only has one input (at the top/side) and one on the top surface, or at least what I assume to be the top?