Fiesta MK3 TDI build

[21-AARON-21]

My slowww unreliable 1.8D quartz gets transformed into sumthin respectable!

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[mackers]

No pics? What are your plans? Im only down the road from you.

[21-AARON-21]

ive just finished the engine swap last week. pics and a writeup to come soon, sorry ive been buzy enjoying a bit of boost!

[mackers]

Nice one, I was thinking of doing this conversion a few years ago but got side tracked and never got one. Cant wait to see the pics, should be a cheap fun car.

[cossiejsy]

get some pics up please

[G950KDT]

pics! glad to see another tappety derv mk3 coming along on here!

[21-AARON-21]

ok im new to this i took 3 hours to rite up a guide to do the engine swap. i then tried to wack in a picture and sure enough my giant 3 hour guide goes byby! bollocks! il write it again 2mo nite if im not buzy! my apologies all yous lookin some photos il take some more 2moro. Theres a nice one of my engine about to blow after some err overheating issues! lol

[21-AARON-21]

3 PICS ABOVE ARE HOW IT USED TO LOOK BEFORE I WENT ABIT MAD WITH FIBREGLASS!

HOW THE ENGINE ARRIVED...



AFTER SOME TLC IT LOOKED LIKE THIS....


CAR AS IT IS NOW...



PLENTY MORE PICS TO COME AND ILL WRITE THE GUIDE AGAIN
THANKS

[Glenn.]

Looking forward to seeing the pics.

[Pob]

Hi mate, can i ask what car is the engine out of??

Plus, is the starter on the back or the front of the gearbox?

I've never messed about with diesels much, i take it you dont need much in terms of wiring?

[21-AARON-21]

Im not 100% on it but i think the engine came out of a mk1 mondeo i think as it is the 1.8 td not the endura de td. Starter is on the front just behind the radiator. The mondeo had an ECU my 1.8na didnt have much wiring just the essentials, the fuel pump had an immobilizer on it so i had to cut away the shield and use the 12v live feed off my old pump to hot wire the immobilizer solenoid. No other wiring issues otherwise.

Im having major overheating problems after about 10 mins of driving its in the red on temp gauge, and water is boiling up in the header tank!! Ive taken out the thermostat with no change checked all coolant pipes for leaks, and theres no oil present in the coolant or coolant present in the oil. Theres no loss of power. i was thinking it was a head gasket failure? any other ideas as to what it could be? possibly connected up the cooling lines wrong?

[mackers]

Nice little project, I remember a few years ago a guy put the TD in his mk3 fiesta. Its on fiestaturbo.com and im sure it could give you a few more ideas to look at it. What other plans you got. Where did you get the engine out of over here?

[21-AARON-21]

I think ive seen the thread act. Well i think i got what i paid for... got it for 130 from a guy breaking it in belfast. i saw it in the car before it was removed but i was stupid as i didnt see it running first, just took his word for it, which is a mistake il definately not do again! It drives well but a mate suspects the head gasket. i went and bought the 70mm torx key for the engine head bolts should worst come to worst and i have to swap the heads of the two engines over the next two days. on the bright side im gaining valuable experience lol

Other plans for the car are bit of a body kit to allow clearance for the 16". I have wide arches, skirts, escort rs bonnet vents in bad boy bonnet, cosworth style lip on the si bumper, smooth boot, relocated plate onto bumper. Car is not a long way from finished bodywork wise, the main work is done, it just needs smoothed out. itl be resprayed performance blue once finished. Interior plans are smoothed dash with lcd screen and a selection of gauges im waiting on organised on it. I have Si seats in there, may get the seats recovered. Ive a nice ice install in the boot with false floor and custom sub box on the driverside, i have a mates blown sub that is the same model as my sub, and i wil cut the front of that off make a fake sub and a custom box for the other side and hide bits in there. I have loads of pictures off all work i have done, so il probably do a separate thread showing the bodywork. So itl look and gooo pretty well hopefully!

[G950KDT]

nice one mate, where did you get the hardpipe kits from? look nice!

im doing my van atm and was toying with the idea of taking the towbar off to put SI bumpers on, think i might just do this now they look pretty good with the right stuff done to it

look forward to reading up on this one.

how much did you have to change to do the turbo engine conversion was it straight in and out from the old 1.8DI engine?

[-beefy-]

loving the diesel dumpvalve lol ,


but fair play to you fella, making do with a diesel lump , there quite pokey in the midrange ,



just loose the audi badge , folk will think you got a rattly rs4 lump in it lol


keep up the graft ,


beef

[jimmy16v]

i done this conversion on a escort van a few years back,i also had a overheating problem turns out the rad fan was wired wrong so it was blowing hot air through the rad,of course this didn't matter when sat in traffic but on the move it would overheat.i switched the wires and all was fine

cheers,jimmy

[jghs83]

nice thread dude,

http://www.mwstewart.co.uk/articles/mk3enduratdi/

check out the link, it might have some info for you if you needed it

[21-AARON-21]

Hi i got the universal 2.25" pipe kit and intercooler for 130 all in off ebay from tuningpartsbay. Buy it now it comes to about 170 i think but i got mine in auctions from the same seller. The Si bumper are a big improvement over the quartz thin black bumpers so go for it. Im sure you could keep the tow bar with a bit of cutting if its needed.

As for the swap it theres are a few clearance issues
1) alternator on the TD is on the back, for the fiesta i used my 1.8D atlernator and bracket to put it on the front under the fuel pump. The alternator pulley needs changing as it fouls the chassis so the 1.8D fiesta one is needed.
2) The oil filter will stop you getting the engine in right so it needs to be put on after the engine is in. Not too difficult to get at from underneath.
3)The injection fuel pump needs to be attacked with a grinder and you need to carefully remove the security shield covering the immobilizer solenoid so it can be either swapped for the one on the old pump or hotwired to open with an ignition live feed.
4)The brake servo and master cylinder get in the way of the turbo compressor inlet and outlet so it needs to be moved 10cm to the right and the servo linkage cut and extended
5)Cooling pipes will need to be custom jobbied by urself to fit the fiesta. I went to a scrap yard and got one of a td and straight d and combined the two where needed to get it working.
6)fuel lines may need to be adapted a bit. I used the mondeo ones that look neater than the fiesta so they went left around the engine timing cover and around the back.
7) the exhaust needs to be changed for a 2" one again a custom job to get it to fit the fiesta neatly.
8) intercooler... some come without but if you want one the top mount may not fit in the fiesta i dont know as i fitted a FMIC so you could either buy a FMIC or the standard top mount or without. FMIC approved by myself tho for plenty more power and potential with a bit of tuning.

If your 1.8 lump is good and has low miles you could just buy the bits i mentioned above, fuel pump, fuel filter...optional, coolant and fuel pipes, turbo, inlet and exhaust manifolds.

The diesel dump valve, i know theres no point on a diesel really except for noise but i love the noise havent bothered getting it working yet. It is just a cheap ebay one, i need to get the vacuum solenoid valve and microswitch to get it working, which i didnt know when i bought it. I know this one will make the pssshhh sound, how do i get the turbo chatter sound is that a recirulating dump valve?

It doesnt have the Audi RS badge anyway,thats how it used to look before i went a bit mad with the fibreglass. ive done plenty of bodywork since making a wide arches to make clearance for alloys, skirts, smooth boot, escort rs vents and subtle bad boy bonnet, Cosworth style front lip on the Si bumper. And plate relocated to rear bumper, Roof luggage rack lines filled in, smaller mirrors and Rs style spoiler made a bit bigger. Most of the work is doen but its rough, just needs smoothing out and painted
Its a great improvement of the standard 1.8lump!

I checked the direction the fan was blowing, it was going the right way thanks for that suggestion. I figured it must be the Head Gasket Failure so i took the head of the car and the gasket was pretty bad. Usually Head Gasket Failure is quite serious but as i have a spare engine to get parts off its only an inconvenience to me. Il use my 1.8D lump head and fit the Td valves, they are exactly the same but i think theyl be in better conditon than my old engine. Im just about to go out now and get started stripping the valves from the 1.8TD head, then il rebuild using the 1.8D head. I dont have a valve spring compressor but i used a 27mm piece from my socket set to remove the valves by applying pressure to the spring it allows the 2 metal keepers to pop out. Its a bit tricky sometimes but thay all came out ok. I hope they go back in ok or i may have to buy the proper tool!Il make sure to take a few pics of this too to go in the guide....that i will get around to eventually! lol

Thanks for all the comments and suggestions! much appreciated!

[XRMike]

Ive done a TDi conversion to a mk3 too. Theres only a few of us that have managed it.