K163TRH fiesta xr2i 16v, my first love, engine update all built up

[G950KDT]

looking nice mate! great progress!

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[jon_ross]

small update on the build, firstly ive made up a braket to mount my cossie fuel pressure reg and ive also sorted the engine loom out, its not much atm but im skint like everyone in january. heres sum pics of the pressure reg







ive also ground off the top so that when south coast performace set it up they can fiddle with it

one nite i was bored so out come the manky wiring loom id been putting off. it wasnt a hard job just messy and sticky. heres the loom as it came out, wot a mess!!





i un piked wot was left of the insulation tape marking were connetors split from then cleaned it up abit. this is wot i found under the insulation tape





above pics is the coil wiring! the twisted to gether bit is bypassing a block connector it used to belong in and the wire that was used to replace it was realy hard, brittle and folded up (no wonder ive allways had ignition problems on and off)

so soldered and insulated properly using decent wire





while i was sorting the loom out i discovered i had a watcher





ive got 4 cats and when ever your doing somthing like fitting a plug or setting up the entertainment system, or repairing looms! shes there watching and the others just aint interested.
heres the connector that was bypassed. it also had most of the wires almost broken so i just cut each wire one by one and added a small piece of wire to keep the lenth right









then i was just left with the task of retaping the whole lot up





the next plan is to get the car done to the point of were it can go to my mate so he can do the body work. i dont need to do too much so it will be done in the next 2 weekends

[jon_ross]

right peeps bit of a large update for this one as i need it back on the road. i managed to raise the funds to sort it out properly so ive ordered all the parts i need apart from 2 or3 parts so here goes

ive still got small jobs to do on the car so heres the pics of the weekend i clean it all inside and out









i removed the seats because the last time i fitted them i was in a rush and fitted them n/s to o/s and o/s to n/s







also my son has to ride in only the best aswell so some money was put aside for this beauty.
its almost too nice to ruin!!



right, now remember the gearbox story?? heres some pics of what i did to the first gearbox

















also all the bearings had exploded but i didnt take pic as you can imagine what a pile of metal fragments and ball bearings (some balls were split in half!!!)
so i got on the phone to G.E.A.R.S (gearbox engineering and rebuilding services) as he built the first one and was faultless til i fucked it. I was going to buy all the needed parts but because i needed both main and gear shafts plus needing them modifiyed to fit my spec box it would be cheaper to just buy another one. but this one is abit better spec. its got better over sized roller bearing, altered gear ratios, stronger sycros and selectors, diesel final drive, escort lsd set to 90nm instead of the 60nm standard, and a modified s1 rst casing to accept bigger gears and bearings





after a lick of paint



right now back to the car ive fitted the 2nd hand pump and sender into the tank and cut out those bodgey brake pipes which were realy soft so wouldnt of lasted much longer. as the brake hose braket was on incorrectly and i had already made the pipes up i removed i bracket which were rotten behind anyway and welded them on in the correct position and fitted the pipes and fuel tank and then run new braided fuel line as mine was really brittle all the way to the engine bay



















remember me mentioning that the o/s subframe leg had rotted and broken again well heres the fix
what did was i put a jack under the subframe andremoved the bolt and rotten captive nut, then measured on the good side from the bottom of the chassis leg down to the subframe and jacked the other side to match the measurment then chop ed out the rotten bit and made a new base and cleaned up the captive nut coz i couldnt find a nut to fit. then bolted it to the subframe then built up the sides useing 2mm sheet steel for everything, and then gusseted the sides so everything inculding the base is double skinned

















while i was in the engine bay with the welder i done the engine mount bracket aswell



also i finshed re painting my rocker cover. i got my mate to shot blast it and i took my time doing it this time and it looks sweet



i have started building the engine but im going to save up the pics from the head build and the engine build and do them as one update but here some pics of some parts ive got ready to go







hope you like

[jon_ross]

right peeps this is the engine updateso hear goes starting with the head

i started with a standard head and thought id try to do my best head yet (as ive ported a few now) so heres some pics of the rough porting and smoothing of the combustion chambers









it looks rough there but i had not smoothed them out yet, this prosess was to just get the size of the ports right. also i ported and smoothed this breather plate as i didnt think to do that last time



once id finished the ports apart from polishing them i had the head skimmed by 8 tho for a bit more compression (max on zetecs is 10 tho)



i then polished the combustion chambers and smoothed ports and posished. i couldnt get a good pic of the ports though coz when you really close the flash reflects back and when you do it without its just a black hole so heres a pic of one of the polished chambers



heres some pics of it built back up and ready to go!i spent 4 hours putting it to gether in my kitchen stuffing my face with lindor truffles

]







also i got this from a car i was breaking , it was very corroded but ive cleaned it up and im going to paint it black




and now for the engine , heres the bottom end built back up



and heres some of it built up ready to go!!!













looks sweet i think. i cant wait to fit it now, and i start working for south cost performance next monday and boss said i could finsh it there so it will get done quicker (yay) just waiting on my techniclutch now

[andy130]

looks good so far mate

[xrmalin]

looks like youve put your heart into this good luck with the rest of the build and good luck in the new job

Cheers mark.

[jon_ross]

Originally Posted by xrmalin

looks like youve put your heart into this good luck with the rest of the build and good luck in the new job

Cheers mark.

cheers for comms guys, i have definntly put my heart into it, i have a funny connection with this car.

thanks for the luck, i cant wait im buzzing about the job after ages dropping hints that i would do anything for a job and always helping them out ive finally landed a job in the type of garage that ie always wanted to work in, a cosworth tuning specalist!!!!
:b anana:

[Fiesta_ie]

nice work i done the same to mine when i fucked my headgasket but spend more timo on the head heres the pic


what´s the brand of your spark plug cable??

[jon_ross]

thats looks sweet mate, it took me 35 hours to do this one as i worked it out this time. i dont know how that bloke at cylinder head developments does it day in day out, id go mental. its much better than the last one though , very similar to yours

[Fiesta_ie]

your have the ports more open than mine, I was afraid to reach the water channels and oil. just skimed a little bit, gave a touch in the divison zone spent more time polishing it.my fingers hurt for a long time lol

[jon_ross]

Originally Posted by Fiesta_ie

your have the ports more open than mine, I was afraid to reach the water channels and oil. just skimed a little bit, gave a touch in the divison zone spent more time polishing it.my fingers hurt for a long time lol

ive got a head cut in half so i can see how far i can go and theres loads of material to cut out on zetecs, i could of gone more but i couldnt be arsed in the end, it kills your hands dont it

[wess-rs]

That looks awesome!!

[cossiejsy]

Thats looking stunning

[Fiesta_ie]

Originally Posted by jon_ross

ive got a head cut in half so i can see how far i can go and theres loads of material to cut out on zetecs, i could of gone more but i couldnt be arsed in the end, it kills your hands dont it

yes it does lool
can you give me a pic of the half head to see the ports?? what the brand of your spark plugs cable? send me by pm ;P

[jon_ross]

cheeRS for great comms peeps, i need it with this one as not alot of people seem interested

[jon_ross]

fiesta ei ive pm'd you mate

[tezmanian devil]

looking good dude.
i'd avoid goin to the unit for abit, i kinda scratched your rocker cover
































had you goin i bet

when you getting this shed back on the road then?
you working at south coast now?

[jon_ross]

Originally Posted by tezmanian devil

looking good dude.
i'd avoid goin to the unit for abit, i kinda scratched your rocker cover
































had you goin i bet

when you getting this shed back on the road then?
you working at south coast now?

YOU CUNT i just shit myself, i hate you sometimes. i went up the unit the other day and saw you had done some tidying IN YOUR END!!!! could of done my bit aswelllol, only joking i realy need to get sorted up there. yes i am at south coast now so WEY HEY and its awsome. we had a brand new focus rs in today for a power run and in had the stage 3 convertion and pulled 373bhp! and as for my 'shed' its going down scp tomorrow with all the bits and im going to get cracking pete said he would help me wet sand it and mop it aswell

[tezmanian devil]

bargain, should be back up and running shortly then?
dont supose pete or mark have had any luck sourcing and wrc spoiler for me have they? got my wrc bumper earlier... all the way from norwich and then my wiper motor packed up just as i was leaving to come home so had to drive back in the rain with no wiper's
wanting to get it painted soon so getting pretty desperate for a spoiler now!

[rs_traynor]

looking good mate....car needs a good buff tho looks abit dull/orange peel

[jon_ross]

Originally Posted by rs_traynor

looking good mate....car needs a good buff tho looks abit dull/orange peel

cheers mate, yea i know what you mean im going to do it with the help of mt mate pete whos awsome with the mop and were going to wet sand it and mop it and see if will need a blow over, but i put 5 coats of red on and it was my first ever paint job and first time using 2 pack paint. cheers for good comms, jon

terry ill remind pete 2muz and ill see you 2muz aswel

[warrenpenalver]

a higher res photo of the speeding incase you want to build a car file of its life:

[fezzajsy]

coming along nicely man

[tezmanian devil]

where's the update's on this then, dont forget to mention the head gasket insident lol

[jon_ross]

Originally Posted by tezmanian devil

where's the update's on this then, dont forget to mention the head gasket insident lol

you bastard i wasnt going to mention that!!, im going to to a big update very soon

[jon_ross]

hello peeps small update. sorry it hasnt been for ages but ive had quite a few headaches and delays with the car so ill start from the begining

when i got my job at scp my boss mark said i could take all the stuff in my unit down to the work shop to make it easyer and save me money so the car was towed with no engine and no light in twilight darkness! the next weekend me and terry eptyed the unit including his black escort and my saph

the next weekend i painted the engine bay and during the evenings after work i stared to working on it again, its so much easyer with a ramp



and aslo my toolbox right to hand instead of loads of tools piled in a small toolbox, ending up on the floor and getting lost



first job was to bolt the engine and gearbox to gether. I was going to use a ebc organic clutch cos i had one before and there faultless and have a light pedal feel. Typicly i forgot my camera the night i put the engine in and my fone aint even worth trying.
After a very late night putting it all together i couldnt start it as i had no fuel, oil, gearbox oil, coolant, or volts in the battery.







the battery went on charge over night and i got some fuel to take with me and got the oil i had in my shed that i niked from hi-Q were i used to work. I had to connect the fuel lines because due to fitting braided lines i couldnt remember which was which so i had to put fuel in and switch the ignition on and see which line spat fuel at me. the next step was to oil her up so in went the gearbox oil no problems, then moved on to the engine and pourer 4.5 litres of oil into the engine and it just sat in the head
i could just see a deep puddle of oil in the filler hole, then i noticed a drip and found oil running down the block!!!

so off with its head!!!



i found i had put the head gasket on upsidedown so i kinda lost my temper abit and kicked my fog light out witch inturn broke my big toe



so after a shit load of shit ripped out of me my my work mates and terry i refitted it proplery and twas all good

the thing was when i built the engine i didnt start till late in the afternoon and were i took so long being carefull building the bottom end i forgot time existed for a while and it was very late when i finished it but i was despirate to see the engine together i persisted and my tiredness bitt me in the arse

so on to starting well baisicly it dosent at this point im wondering what sausages taste like cooked off and xr2i

first port of call was to check for spark, that came back ok. then i checked the fuel found the injectors to be fireing and fuel getting to the rail and fuel pressure was fine at 3.5bar but then i put my power probe to the cut of switch wire which ive cutout and soldered together with a take off and found that the pump primes when i turn the key then it goes back to earth as normal but when i crank it the wire stays earthed and when you throw a live to it, it still doesnt fire!

i found i needed a fiesta si loom due to the edis control unit so i got a loom and fitted it and was worse off. I had no fuel or spark now!!!
i removed the loom and checked over the whole thing and it was fine

i found that due to the loom being a pats loom and the ecu a non pats there was differences in the pins in the ecu but no matter were i looked or who i called i coulnt get the exact pin data for the deep ecu and the exact wiring diagram for the si loom, so plan B was to revert back to my original loom and get an EARS ecu from an atuo mondy or rs1800 one. The story behind that is my mate woddy who lives fooking ages away from me has a garanteed working ears ecu and he only wants 30 quid for it but hes taking his time sending it to me. In the time ive been waiting ive finshed the whole car even some extras like fitting a new fog light and some road legal hid look bulbs in every light, fit a oil pressure gauge for peace of mind, and had it fully sign written on the windows of the south coast performance advert and given her a clean. I will take some pics tomorrow but its dirty again.

the next step is to start to lightly wet sand the paint and mop it then sort out the damage to to the door and hopefully some time this year i might get my ecu and get her running and on the road (rolling road that is).

im going to do al lthe runnig in mileage on the rolling road and then set up the cam timing and remap it and hopefully see 170BHP and more in torque from a non turbo motor

pics to follow

[jon_ross]

right here goes peeps massive update including the finsh (for now). The reason i havent been updating as ive been very busy at work and when i found the mistious problem of no or weak spark and constant fuel pump (even with ignition off) and still not start, and also what i had to do to get it going resulted in me losing all interest for a while and once regained interest and got back to work there was alot of work to do so camera stayed on the side for most details but ive got enough to see the story.

also just got to say if you read performance ford then you may have seen the east sussex rsoc meet we have in this months issue and seen my car on the left on the main pic, and yet when you red it noware does it mention me and i save my guts out everyday on that ramp (it even had my current job at the time, the white esort having new big end and topend rebuild). also i was the only one that went to FITP from SCP and me, the mrs and my boy took the fiesta cossie (done donuts in the grass, mrs shit herself, boy cracked up laughing and i got a bolloking from a ginger cunt) still no thanks and also only got one crummy little photo in the mag and i was on there stand!

anyway back to my car

the story from here goes

When i got the ears ecu i set about fitting the orginnal loom back on and pluged in the ecu and still no start and constant fuel pump and no or weak spark, so i got poking around with a power probe and found everything was interfearing with everything else so i decided to get the dash out and see what going on and what i found was the burnt out wire i found and repaired a while back went alot further back and had burnt out a main part of the loom. so now i needed a 180 xr2i complete loom!!! after a month i still coundnt find one and then and silver rs1800 poped up in the fort sale bit of fast ford and snaped it up for Ł350 heres some pics to ease the bordom













also has iwas making the engine bay nice i thought id best make the outside look nice too, so i started wet sanding and moping the sand paper paint work



more to come on that. i did the whole front end and tokk me 4 hours
going back to the rs1800 for a second. I had to travel all the way to bristol to get it but it turned on well worth it. when i got there i was presented with an rs1800 with no more than a completly nakerd shell. There was rot in places id never seen before and all the usual places gone to the extreme. The worst bit was the n/s/r suspention turret was so rotten it had completly ripped out and smashed through the rear speaker panel. unfortunatly i took the pics on my fone and i cant get them on my computer

i wasted no time in gutting the rs but brfore i did i made sure everthing worked ok and then realised id didnt have a heated front screen (yet another job to do). also i had to cut out the very gay alarm that dont let you start it for half an hour. included with th rs was a quite nice and grown on me louvered bonnet witch i do have a pic of and some brand new set of red dot grooved discs, also it had mint seats and door cards and a black steering wheel so yoink









also i niked the inlet manifold (something i never managed to get hold off during the build)







so now i had what i needed on the floor i got to work on the xr starting with striping the loom out of the engine bay and then stripping the interior and removed the whole loom and then fitted the new one before i for got were id all went!

more pics












just a reminder of what sort of driver i am



once i fitted the loom i tried the key again and WE HAD SUCCESS finally it runs and everything worked!!! All i had to to now was cut the heated screen circuit out of the old loom and fit it to mine and cut my clifford alarm out and fit it to the loom. as i got so exited i forgot the camera at this point but it was only wiring but i do have pics of the interior. As i put bits back in i cleaned it all up and it looks and smells awsome, just like new









now all back to gether and all niggles sorted all i had to do was get cleaning which actually ment getting very messey first wet sanding and mopping, anthother six hours later making a grand total of sanding and mopping 10 hours after that i cleaned it off as the compond gets everywhere and that was it for the night

before





after







got loads more pics to do but far too late i cantt keep my eyes open ill finish 2muz a correct all the mistakes

[scottyrs]

well done mate looks really good alot of hardwork gone into that!

[warrenpenalver]

fucking hell i'm surprised you havent scrapped this with all the disasters that keep going wrong with it.

[Zetecfiesta]

glad to see you finaly got it sorted, huge amount of work gone into that!!

[jon_ross]

hello peeps, ive had a very weird day to day. first thing this morning i got some fuel for the car and started it up and all was good so off to the mot station, YAY. it was there for a while as they just squeese our mots in and when it come back, MAJOR DISASTER. The oil was mixing with the water but wasnt over heating:tiff :. but to my suprise i just shruged it off and yea i felt so gutted it felt like my guts were upsidedown and i felt propper sick but i just laughed and said off with its head for the second time then. so instead of driving the car home, i stayed late yet again and got the head off and while i was in the prosess i drained the coolant and it was just oil, creamy fucking oil from that point i just new it wouldnt be the gasket. when i got the head off i found that the gasket was perfect and you could easly see with the creamy oil so the problem is either cracked block or head. im going to have the head crack tested and hopfully comes back ok as i sent fuck loads of time on the head and id rather rebuild the bottom end than port another head that neatly.
ive gone to far now to give up. it would be such a waste of time and money, and it passed mot with no advisorys!!!! i just think that maybe its just paying me back for the 3 years of constant shit and abuse i gave it. i going to load upsome other pics 2muz including the mess its it now.

[jon_ross]

Originally Posted by warrenpenalver

fucking hell i'm surprised you havent scrapped this with all the disasters that keep going wrong with it.

hi mate hows you?? you wound belive how many times i wanted to just break it but each time i just cant bring myself to the final decision so i just plod on. i think its cos there not one part of the car i havent fiddled with and theres not much left of what i bought off you, lol. Its still the best Ł500 i sent though, even though it did try to kill me at the first roundabout i got to as it had next to fuck all brakes! lol. how did you drive that car man??? and who worked on it when you had all that work done cos the next day at work i bled the brakes and nothing come out of the front for ages and then when i went down the road and tryed it, it was like hitting a brick wall compared, but when i braked hard the rears locked up easy so i had to do the shoe and slaves, i hope you dont use them anymore, jon

[jon_ross]

cheers for other comms peeps.

[warrenpenalver]

Originally Posted by jon_ross

Its still the best Ł500 i sent though, even though it did try to kill me at the first roundabout i got to as it had next to fuck all brakes! lol. how did you drive that car man??? and who worked on it when you had all that work done cos the next day at work i bled the brakes and nothing come out of the front for ages and then when i went down the road and tryed it, it was like hitting a brick wall compared, but when i braked hard the rears locked up easy so i had to do the shoe and slaves, i hope you dont use them anymore, jon

I was used to non-servod brakes at the time i sold that.

That garage was the base garage and are a bunch of cowboys

[turbochild]

this seems like it's been a real labour of love i'm sure the persistance will pay off though

[jon_ross]

i just want it back on the road now. im sick of working on it. once its all gud i might see how much i can sell it for.

[jon_ross]

[jon_ross]

above is video on rollers 148.8 bhp atw

[fezzajsy]

[tezmanian devil]

R.I.P