Escort RS Turbo EFI Project II E353 HPC
12-08-2009, 06:12 PM
#82
Car went on the rollers again today at jkm and managed a measly 155.7! horses at approxiamtely 13psi held with afr's averaging about 10.5 so overfuelling 
Now I think, I have gone as far as I can locally, with the fiesta turbo management so have booked in for the 534 miles round trip to msd, blackpool. So now its roll on Monday 24th August where I hope, they can squeeze the potential out of her!
Disappointed but not depressed
Now I think, I have gone as far as I can locally, with the fiesta turbo management so have booked in for the 534 miles round trip to msd, blackpool. So now its roll on Monday 24th August where I hope, they can squeeze the potential out of her!
Disappointed but not depressed
18-08-2009, 10:23 PM
#83
Been having some gearbox issues. That didn't last very long and hadn't even tried to break it.
Decided if I'm playing gearboxes this week then I'd do the mk5 pedal and quadrant mod as the cars currently using an ap 4 paddle...plus its a worth while mod.
Dropped by fords and got a few bits.
Spare filter, rocker gasket - as the old rubber one is starting to weep, mk5 pedal, quadrant, bushes and an expensive crankshaft oil seal.
Fitted the pedal mod. What a bitch of a job. Took the seat out and spent a few hours upside down lol.
Then cracked on and took the gearbox out.
Checked the clutch - which will go again.
Look pretty terrible in the pic above but in reality is fine.
Ordered up a new release bearing as the old one was noisy.
On the job card for tomorrow is;
1. Fit crankshaft oil seal (flywheel end)
2. Fit (yet another - should get shares in Payen!) sump gasket - Would be wrong not to when its in such a good place to get at it.
3. Replace NS CV boot - pin hole leak making the wheel dirty
4. Sort steering column bushes
5. Try to source and fit a garratt -34 actuator. After recently buying a new Collins -31 I've been led to believe a -34 will be more suited to my spec! joy. Anyone interested in an 'as new' -31 collins give me a shout!
6. Order reverse light switch - mine's leaking
7. Re-think current positioning of coolant rad and possibly cooler as actuator is scarily close to spanking new rad!
8. Fit new pad fitting kit - Ordered from Big Red (Caliper re-manufacture company) as old pins are fooked and keep working loose.
9. Think about getting my head around buying cts stage 2 gearbox
10. Get my head around buying gearbox
11. Drive, pay for and return with new box
5 days from tomorrow to get this car back on the road and up to blackpool...No pressure
Cheers
Decided if I'm playing gearboxes this week then I'd do the mk5 pedal and quadrant mod as the cars currently using an ap 4 paddle...plus its a worth while mod.
Dropped by fords and got a few bits.
Spare filter, rocker gasket - as the old rubber one is starting to weep, mk5 pedal, quadrant, bushes and an expensive crankshaft oil seal.
Fitted the pedal mod. What a bitch of a job. Took the seat out and spent a few hours upside down lol.
Then cracked on and took the gearbox out.
Checked the clutch - which will go again.
Look pretty terrible in the pic above but in reality is fine.
Ordered up a new release bearing as the old one was noisy.
On the job card for tomorrow is;
1. Fit crankshaft oil seal (flywheel end)
2. Fit (yet another - should get shares in Payen!) sump gasket - Would be wrong not to when its in such a good place to get at it.
3. Replace NS CV boot - pin hole leak making the wheel dirty
4. Sort steering column bushes
5. Try to source and fit a garratt -34 actuator. After recently buying a new Collins -31 I've been led to believe a -34 will be more suited to my spec! joy. Anyone interested in an 'as new' -31 collins give me a shout!
6. Order reverse light switch - mine's leaking
7. Re-think current positioning of coolant rad and possibly cooler as actuator is scarily close to spanking new rad!
8. Fit new pad fitting kit - Ordered from Big Red (Caliper re-manufacture company) as old pins are fooked and keep working loose.
9. Think about getting my head around buying cts stage 2 gearbox
10. Get my head around buying gearbox
11. Drive, pay for and return with new box
5 days from tomorrow to get this car back on the road and up to blackpool...No pressure
Cheers
Last edited by Danster76; 18-08-2009 at 10:30 PM.
19-08-2009, 07:26 PM
#87
A few parts arrived this morning so cracked on.
DONE
DONE
DONE
NOT DONE
DONE - ARRIVING BEFORE 1PM TOMORROW - TA MSD
6. Order reverse light switch - mine's leaking
[/quote]
DONE - FIT IN THE MORNING 2 SECOND JOB
DONE
DONE
DONE
Back in with the clutch and have a think about it...
DONE
DONE - 200 miles later and she's on my shingle!
Fingers crossed, she should be back on the road tomorrow afternoon...
Opt'd for a cts stage2 quaife diff jobby.
Cheers
DONE
NOT DONE
6. Order reverse light switch - mine's leaking
[/quote]
DONE - FIT IN THE MORNING 2 SECOND JOB
DONE
Back in with the clutch and have a think about it...
DONE
DONE - 200 miles later and she's on my shingle!
Opt'd for a cts stage2 quaife diff jobby.
Cheers
Last edited by Danster76; 20-08-2009 at 03:39 PM.
20-08-2009, 03:29 PM
#88
Got on with it again this morning.
Ready to load
Can just make out the quaife diff oil ways in this pic
Painted some stuff
Loaded...just!
Didn't finish it today as ROYAL MAIL stopped play by NOT delivering my -34 which was on a next day b4 1pm. What a load of bolloxs. Apparently its rolling around in Milton Keynes and will be with me tomorrow. Fookers. Ah well. She'll wait. Did lots of tinkering and tidying to pass the time
Cheers
Ready to load
Can just make out the quaife diff oil ways in this pic
Painted some stuff
Loaded...just!
Didn't finish it today as ROYAL MAIL stopped play by NOT delivering my -34 which was on a next day b4 1pm. What a load of bolloxs. Apparently its rolling around in Milton Keynes and will be with me tomorrow. Fookers. Ah well. She'll wait. Did lots of tinkering and tidying to pass the time
Cheers
Last edited by Danster76; 20-08-2009 at 03:44 PM. Reason: Added pics
21-08-2009, 08:33 PM
#93
Yeah Loz said the engine build was begining Monday. I'll pop in on Tuesday when I'm back. You got a few days off to get some headway. Let the fun begin! Bet you can't wait. I couldn't!
Next on the list...I'm nearly there I think...
Sort out brake light switch, I must have upset it doing the clutch mod. Just needs adjusting as they're staying on all the time
Will sort that in the morning or if the mrs goes to bed in a bit might do it now!Clean it and wait till Sunday when I'm off to Blackpool to get it sorted.
I was going to preload actuator and set boost but its pointless as its only gonna get done again. Probably taking it up on a truck now which will keep it clean and probably use less fuel than the car!
21-08-2009, 08:53 PM
#94
Pics are a bit boring today! Have got on well though and SHE'S WORKING AGAIN!
actuator arrived this morning along with a new reverse light switch.
Fitted it all up and finished fitting the box. Filled it up with the lovely oil (3.2 litres) 75/90w fully synth.
I changed the rocker cover gasket once the engine crane was out the way.
Let it warm up and then ran the box and noticed a noisy wheel bearing! For fooks sake! wheel off, stripped down, OSF bearing mullered. waited for replacement to be delivered. I had to go and do some real work for a bit so left loz to finish the job off.
He finished it and even touched up the caliper! Good boy.
I drove her back to my place and all seems fine. So far, no leaks whatsoever, sump, rocker, CS oil seal and box all good Fingers crossed x
It was all fine till I run out of fuel 50 meters from the petrol station! lol
All in all a good week. Hopefully now everything is sorted and ready for MSD on Monday. Can't wait!
Cheers,
Heads still all sparkly!
actuator arrived this morning along with a new reverse light switch.
Fitted it all up and finished fitting the box. Filled it up with the lovely oil (3.2 litres) 75/90w fully synth.
I changed the rocker cover gasket once the engine crane was out the way.
Let it warm up and then ran the box and noticed a noisy wheel bearing! For fooks sake! wheel off, stripped down, OSF bearing mullered. waited for replacement to be delivered. I had to go and do some real work for a bit so left loz to finish the job off.
He finished it and even touched up the caliper! Good boy.
I drove her back to my place and all seems fine. So far, no leaks whatsoever, sump, rocker, CS oil seal and box all good
Fingers crossed xIt was all fine till I run out of fuel 50 meters from the petrol station! lol
All in all a good week. Hopefully now everything is sorted and ready for MSD on Monday. Can't wait!
Cheers,
Heads still all sparkly!
23-08-2009, 05:22 PM
#99
Advanced PassionFord User
mine made 169 on std t3 just put the stage 2 t3 on and was hoping for nearer 200 but worried now you will have to let me know how you get on good luck
23-08-2009, 05:38 PM
#101
Advanced PassionFord User
superchips one on ofac management yeah want to after all the money and time on it but not sure by who went to totd last time wat is msd doin to yours is it a live map?
23-08-2009, 05:59 PM
#102
cam timing, set-up, maybe map tweeks if needed. Whatever it takes really! I'm using an evolution chip with ofac so it made sense to travel up. Previously I had a 195 superchip.
With ofac you're limited on tuners but hey ho.
With ofac you're limited on tuners but hey ho.
25-08-2009, 06:41 PM
#104
Quick update.
It didn't go particulary well up at MSD.
Some air leaks main one being servo pipe to inlet. Rest need precautionairy cable ties to secure. In the process of sorting this
Previously my FRST charge carrier/ cross over pipe was cut and made shorter on the outlet for whatever reason I don't know... Result was, the Samco hose to the front mount cooler was stressed and 'could' result in coming off under boost. Never has thus far but its early days.
Again, in the process of sorting this. If anyone reading this has a spare fiesta RS turbo charge carrier lying about then let me know!
My car had an inline fuel pressure gauge and the fittings were not up to spec, hose and julbilee's and was deemed a potential fire hazard so suggested this is removed. I've removed it.
I was questioned why my car had 2 swirl pots. My answer was it came to me this way, which it did. In fact, I think the previous owner got it fabricated by someone on here. I didn't realise that the thermostat housing also acts as a swirl pot so in my mind it had one, a nice shiney one. Anyway, I've removed it and will be up for sale soon. I will need to get a 90 degree samco bend to connect the thermo housing to the rad top hose.
One the day my car showed a waterleak! ffs. Suggested it was the waterpump gasket, coming from that area. After investigating today I've found it came from the inlet manifold and a loose bolt on the underside was the cause. Will be putting spring washers under these when I fit it again.
Fuel pump volts were a bit low at approx 12.8 vs 14.1 on the battery so was advised to rewire and maybe replace the relay? Will look into this and try to get 14 at the pump.
Was advised my ecu should be inside the car rather than fixed to the bulkhead. I did know this but as the car during my ownership isn't going to be used in the wet and will be stored in a nice warm workshop this isn't an issue for me.
Now what aborted the session finally was on inspection of the bores using a borescope on cylinder 3 I was told it was showing signs of early head gasket failure. I saw it with my own eyes and it did look this way. Looked like 2 lines of liquid type residue on the wall of the bore and also around the edge of the piston something had cleaned the carbon deposits from the crown of the piston and the cause of this was logically suggested to be the leak (anti-freeze).
This ended the session and I settled a very fair bill and set off for home.
Today I stripped the bumper off, rad, cooler, turbo, both manifolds etc to get properly onto the head to see what was going on both with the suspected HG failure and the waterleak (which I found was coming from the inlet manifold).
I have the head off and stripped and going to the engineers for a clean tomorrow am. I will then put it back together, maybe tomorrow.
On visual inspection today my opinion is that the HG was ok and no failure had occured. I think the clean part on the piston, which was apparant on all pistons (could see with head off) may have been caused by the fact the car has been over fuelling during the running in period. I don't know what the marks on the bore are but I don't think they are coolant - I have looked and looked at them today! The gasket seal marks on the head are solid, consistent and not showing any breaks or weakness at anypoint, not just around the firing rings.
Slightly frustrated by some on the silly little things which let her down on this visit and think the HG issue which aborted the session was perhaps over cautious but I would sooner it was this way and to make sure things are right. The reason I travelled 270 miles each way for their expertise. It will be 100% for the next session.
I was pretty angry with the car yesterday but after beating the shit out of her today with the spanners we're slowly making up.
Will through some pics up once they've uploaded.
Cheers,
It didn't go particulary well up at MSD.
Some air leaks main one being servo pipe to inlet. Rest need precautionairy cable ties to secure. In the process of sorting this
Previously my FRST charge carrier/ cross over pipe was cut and made shorter on the outlet for whatever reason I don't know... Result was, the Samco hose to the front mount cooler was stressed and 'could' result in coming off under boost. Never has thus far but its early days.
Again, in the process of sorting this. If anyone reading this has a spare fiesta RS turbo charge carrier lying about then let me know!
My car had an inline fuel pressure gauge and the fittings were not up to spec, hose and julbilee's and was deemed a potential fire hazard so suggested this is removed. I've removed it.
I was questioned why my car had 2 swirl pots. My answer was it came to me this way, which it did. In fact, I think the previous owner got it fabricated by someone on here. I didn't realise that the thermostat housing also acts as a swirl pot so in my mind it had one, a nice shiney one. Anyway, I've removed it and will be up for sale soon. I will need to get a 90 degree samco bend to connect the thermo housing to the rad top hose.
One the day my car showed a waterleak! ffs. Suggested it was the waterpump gasket, coming from that area. After investigating today I've found it came from the inlet manifold and a loose bolt on the underside was the cause. Will be putting spring washers under these when I fit it again.
Fuel pump volts were a bit low at approx 12.8 vs 14.1 on the battery so was advised to rewire and maybe replace the relay? Will look into this and try to get 14 at the pump.
Was advised my ecu should be inside the car rather than fixed to the bulkhead. I did know this but as the car during my ownership isn't going to be used in the wet and will be stored in a nice warm workshop this isn't an issue for me.
Now what aborted the session finally was on inspection of the bores using a borescope on cylinder 3 I was told it was showing signs of early head gasket failure. I saw it with my own eyes and it did look this way. Looked like 2 lines of liquid type residue on the wall of the bore and also around the edge of the piston something had cleaned the carbon deposits from the crown of the piston and the cause of this was logically suggested to be the leak (anti-freeze).
This ended the session and I settled a very fair bill and set off for home.
Today I stripped the bumper off, rad, cooler, turbo, both manifolds etc to get properly onto the head to see what was going on both with the suspected HG failure and the waterleak (which I found was coming from the inlet manifold).
I have the head off and stripped and going to the engineers for a clean tomorrow am. I will then put it back together, maybe tomorrow.
On visual inspection today my opinion is that the HG was ok and no failure had occured. I think the clean part on the piston, which was apparant on all pistons (could see with head off) may have been caused by the fact the car has been over fuelling during the running in period. I don't know what the marks on the bore are but I don't think they are coolant - I have looked and looked at them today! The gasket seal marks on the head are solid, consistent and not showing any breaks or weakness at anypoint, not just around the firing rings.
Slightly frustrated by some on the silly little things which let her down on this visit and think the HG issue which aborted the session was perhaps over cautious but I would sooner it was this way and to make sure things are right. The reason I travelled 270 miles each way for their expertise. It will be 100% for the next session.
I was pretty angry with the car yesterday but after beating the shit out of her today with the spanners we're slowly making up.
Will through some pics up once they've uploaded.
Cheers,
25-08-2009, 09:07 PM
#105
Some pics
Ready to set off.
Today went from this...
To this...
Offending servo vacuum pipe clip (One below the jubilee clip)
Once head was removed
Thinking about it. I think what we mistook through the bore scope for being watermarks on the bore were infact traffic film remover (TFR) stains from when the block was cleaned. I remember seeing them when honing the bores. They are just visable on other cylinders too but more so on #3 for some reason.
Will crack on again tomorrow no doubt! lol
Cheers!
Ready to set off.
Today went from this...
To this...
Offending servo vacuum pipe clip (One below the jubilee clip)
Once head was removed
Thinking about it. I think what we mistook through the bore scope for being watermarks on the bore were infact traffic film remover (TFR) stains from when the block was cleaned. I remember seeing them when honing the bores. They are just visable on other cylinders too but more so on #3 for some reason.
Will crack on again tomorrow no doubt! lol
Cheers!
26-08-2009, 08:14 PM
#106
Advanced PassionFord User
shame bout the set up mate but better safe then sorry hope all goes well when it all back together was there any good points to the session ?
26-08-2009, 08:30 PM
#108
Advanced PassionFord User
no sorry mate didnt mean it like that yeah if thats wat they say is wrong yeah just wondering if they said anything bout the engine itself did it sound healthy
29-08-2009, 11:02 PM
#110
Right. Shes back together and running.
This is whats happened.
Removed fuel pressure gauge
Removed swirl pot and fitted new pipework supplied ever so quickly by Roose
Replaced headgasket (payen), inlet manifold gasket (payen) and stud nuts, thermostat housing gasket (ford).
Fitted servo pipe fitting
Clipped up all pipe work
Replaced map sensor vacuum pipe as was looking tired.
I've refitted my old charge carrier for the time being until I get the replacement mainly as I wanted to hear it running.
It ran alright so took it out only to chaff through the lower coolant hose with the alternator vanes! ffs Luckily I noticed what was happening in time so no harm done except to the hose which is foooked. Pulled the front end apart again and got it fixed for the time being with a standard hose borrowed off loz.
Will get a replacement hose arranged on tuesday and hopefully a charge carrier. Then all I need to do is try and get 14 volts at the fuel pump then she's good to go back up to blackpool.
Here's some pics,
Cheers
Painted a few more bits. Alternator bracket, adjuster and heat sheid and thermostat housing. Head back on
Back together - missing charge carrier and rad top hose to thermo
Borrowed pipework
A little video. Not sure if this will work but tried
<embed width="448" height="361" type="application/x-shockwave-flash" wmode="transparent" src="http://i30.photobucket.com/player.sw...2/MOV00105.flv">
This is whats happened.
Removed fuel pressure gauge
Removed swirl pot and fitted new pipework supplied ever so quickly by Roose
Replaced headgasket (payen), inlet manifold gasket (payen) and stud nuts, thermostat housing gasket (ford).
Fitted servo pipe fitting
Clipped up all pipe work
Replaced map sensor vacuum pipe as was looking tired.
I've refitted my old charge carrier for the time being until I get the replacement mainly as I wanted to hear it running.
It ran alright so took it out only to chaff through the lower coolant hose with the alternator vanes! ffs Luckily I noticed what was happening in time so no harm done except to the hose which is foooked. Pulled the front end apart again and got it fixed for the time being with a standard hose borrowed off loz.
Will get a replacement hose arranged on tuesday and hopefully a charge carrier. Then all I need to do is try and get 14 volts at the fuel pump then she's good to go back up to blackpool.
Here's some pics,
Cheers
Painted a few more bits. Alternator bracket, adjuster and heat sheid and thermostat housing. Head back on
Back together - missing charge carrier and rad top hose to thermo
Borrowed pipework
A little video. Not sure if this will work but tried
<embed width="448" height="361" type="application/x-shockwave-flash" wmode="transparent" src="http://i30.photobucket.com/player.sw...2/MOV00105.flv">
Last edited by Danster76; 29-08-2009 at 11:07 PM.
30-08-2009, 02:08 PM
#113
I'm Finding My Feet Here Now
Join Date: May 2009
Location: southampton
Posts: 127
Likes: 0
Received 0 Likes
on
0 Posts
i live in sholing and i wrk in lowford as a mechanic for a garage called europa car company! we pick up alot of cars and the houses on your drive just scream headgend to me! cool car im getting a focus soon to replace my fragile saxo vtr! loved your car when it was in fast ford!
30-08-2009, 02:27 PM
#115
I'm Finding My Feet Here Now
Join Date: May 2009
Location: southampton
Posts: 127
Likes: 0
Received 0 Likes
on
0 Posts
mate ill take yu up on your offer of having a look! pm me! autopaints are good lads so is wessex radiators!
im unfortuantly getting a three door focus 1.6 as being a mechanic with tight bosses they dont like to pay too well lol!
i drive a blue saxo vtr reg v125htr so you may have seen that around! my god its crap lol!
im unfortuantly getting a three door focus 1.6 as being a mechanic with tight bosses they dont like to pay too well lol!
i drive a blue saxo vtr reg v125htr so you may have seen that around! my god its crap lol!
30-08-2009, 08:40 PM
#117
No, because it wasn't a problem then.
I think I pulled the alternator over further when I tightened the belt when I put it back together. Anyway, have now moved the rad forward a bit and its no longer an issue. Just need to get a replacement hose now as the one I have in at the moment is on loan.
Cheers for looking Matt.
I think I pulled the alternator over further when I tightened the belt when I put it back together. Anyway, have now moved the rad forward a bit and its no longer an issue. Just need to get a replacement hose now as the one I have in at the moment is on loan.
Cheers for looking Matt.
31-08-2009, 06:03 PM
#118
No, because it wasn't a problem then.
I think I pulled the alternator over further when I tightened the belt when I put it back together. Anyway, have now moved the rad forward a bit and its no longer an issue. Just need to get a replacement hose now as the one I have in at the moment is on loan.
Cheers for looking Matt.
I think I pulled the alternator over further when I tightened the belt when I put it back together. Anyway, have now moved the rad forward a bit and its no longer an issue. Just need to get a replacement hose now as the one I have in at the moment is on loan.
Cheers for looking Matt.
Looking good Dan
31-08-2009, 07:49 PM
#119
Cheers mate. She's better again! Took her out and gave her some death this eve. The new box with the quaife diff is lovely. Flies!
Just need to get the bottom coolant hose and a replacement charge carrier now. Thought i'd found a nice one from a forum member on here but turns out it doesn't have the mounting bracket
No good. Sure I'll find another soon enough.
Think i'll call msd tomorrow and get myself on the cancellation list as 30th sept which i'm booked in for is a long way off.
Gave her a wash today
Just need to get the bottom coolant hose and a replacement charge carrier now. Thought i'd found a nice one from a forum member on here but turns out it doesn't have the mounting bracket
No good. Sure I'll find another soon enough.Think i'll call msd tomorrow and get myself on the cancellation list as 30th sept which i'm booked in for is a long way off.
Gave her a wash today
