Ford Sierra DOHC renovation and tuning

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04-08-2011, 12:00 AM

ZyNTeX

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Ford Sierra DOHC renovation and tuning

Hi there.

Now its time for me to tell you people out there about my Sierra project.
First of all, my english is now so very good, but i hope you understand what i write. If not, please feel free to ask what i meen, so i can write my word on an another way to make you understand me.

Here's the thing:

I bought this 91model Sierra from a girlfriend of my, because she was broke and don't need this car anymore. It was a big hole right behind the starter motor and the oil sump so i get it very cheap. But the sylinder head was ported and the camshafts was reground for more power. It's about 180hp after what people have told me. (I personally don't know this for sure.)
I decided to rebuild the car and get some lisence plates on it, so i can use it after the roads.

I bougt a used engine from the lokal scrap yard and begin on my way to a very funny car.

The engine is now in the car and i have tried it some days allready. I'm not finish yet with the car, so things will happend in the future.

I have been in touch with a company who tuning cars without turbochargers or compressor, and we have decided that we have to do something with the valves. We are gonna cut the valveseats for better flow and more power, because this is original on this time. I think this will be the last to do with this sylinder head.

Don't worry, i have some other plans in the meen time. I have a turbosharger from an Audi 10v turbo with engine code MC (Audi uhr-quattro) in my garage, so i will try to make some fun out of this. The only things that i need is a new flange and some tubes in 2,25" so i can weld my own exhoust manifold. This will not be a 10sec car on 402m, but i think i will get some fun anyway.

Time for some pics so you can see the car from the beginning and what i have done to this car allready. (The pictures are in chronological order)

This is how the car looks when i started on it.
http://i801.photobucket.com/albums/y...6/DSC_0143.jpg

http://i801.photobucket.com/albums/y...6/DSC_0144.jpg

http://i801.photobucket.com/albums/y...6/DSC_0145.jpg

http://i801.photobucket.com/albums/y...6/DSC_0146.jpg

http://i801.photobucket.com/albums/y...6/DSC_0147.jpg

http://i801.photobucket.com/albums/y...6/DSC_0148.jpg

http://i801.photobucket.com/albums/y...6/DSC_0149.jpg

Checking of rear axle on the right side. Some parts most be replaced from an another one because the rubber was broke.
http://i801.photobucket.com/albums/y...6/DSC_0150.jpg

Original tail lights was all i had on this time, before i get some cooler types.
http://i801.photobucket.com/albums/y...6/DSC_0154.jpg

Water pump, downpipe and manifold off from the old engine.
http://i801.photobucket.com/albums/y...6/DSC_0155.jpg

Checking the condition on cams and sylinder head. (This is the ported head.)
http://i801.photobucket.com/albums/y...6/DSC_0153.jpg

http://i801.photobucket.com/albums/y...6/DSC_0152.jpg

Old engine on his way out.
http://i801.photobucket.com/albums/y...6/DSC_0160.jpg

http://i801.photobucket.com/albums/y...6/DSC_0161.jpg

Here is the reason of why i have to replace new engine.
http://i801.photobucket.com/albums/y...6/DSC_0162.jpg

http://i801.photobucket.com/albums/y...6/DSC_0164.jpg

Old clutch. (Something tells me that this car have lived a hard life before i get it)

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04-08-2011, 11:13 AM

R4N SS

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have corrected the images for you

Quote:

Originally Posted by ZyNTeX

Checking of rear axle on the right side. Some parts most be replaced from an another one because the rubber was broke.

Original tail lights was all i had on this time, before i get some cooler types.

Water pump, downpipe and manifold off from the old engine.

Checking the condition on cams and sylinder head. (This is the ported head.)

Old engine on his way out.

Here is the reason of why i have to replace new engine.

Old clutch. (Something tells me that this car have lived a hard life before i get it)

Some pictures from some old owners of this car.

New engine on his way in...

A mans scrap is an another mans gold! Cheap DTM exhoust for me (Free)

Grill and front bumper mounted.

April 16.2011:

Exhoust mounted.

Hood lifted in back for more cold air intake. (I don't have cooling fans yet.)

From inside of car.

Anyone who see what i have done here? It's gitter in the grill.

Recaro seets mounted.

Engine plate under the car. (I get it for free from a friend of me)

Cd/mp3 player mounted.

Used summer wheels i bought for a good price.

Customization for open air filter.

http://i801.photobucket.com/albums/y...C/DSC_0259.jpg

Coil placed on a new place so the ignithion wire don't hanging everywhere under the hood.

New bushes from rallydesign

I'm not sure what the name of this is on english, but i hope the pictures tells more than 1000 words. (BTW: This is home made)

Flywheel relieved about 3.3kg

Bass adjustment gets a good place so i can adjust it how i'd like it.

New indicators from Poland.

http://i801.photobucket.com/albums/y...C/DSC_0347.jpg

New differential with welded 100% barrier.

Ported sylinder head washed and dismantled

This was all i have for now. I will be back later with brand new pics and updates of what's happend the last time. I have dismantled the exhoust, because this type of shit who was placed on the car was just so i could use it for some day. It was not some original, so this is something i dismantled and throw it as long as i could get it. "New" original exhoust will be replaced after some days. I donæt have all the parts yet. I missing the catalyst, but i have get it just above 40km from where i live...

I look for some new shock absorbers to my car ang get a tips on this here:

What do you people think about it?

Stay tuned people...

Last edited by R4N SS; 04-08-2011 at 12:13 PM.

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04-08-2011, 01:33 PM

ZyNTeX

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Quote:

Originally Posted by R4N S S

have corrected the images for you

Hi there. The reason of why the images don't shows is because i just copy the adress from a norwegian forum where i allready have write allot of things i have done with the car. All other pictures in future will be copyed from photobucket, so then all of them will be shown

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04-08-2011, 02:00 PM

ZyNTeX

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I have not doing so much today, because the weather is not with me. It's raining all the time, so it's not so much i can do. But i have milled out some aluminum in my rims so they will fit the car. Its just one problem i have to solve, but this will take some time. I let the pictures tell what i mean.

Here is the problem. Look behind the rims, and you see that i don't have much space from the absorber to the rims. I will need nome spacers, but now all the company's who sell carparts is closed for today. But tomorrow, i will buy this

This is how the car is standing right now.

As you see, i have to replace the fender. New fender is in stock, but i have to buy some paint for it tomorrow.

Here i have to weld in a new piece, because the old one had dents and was just repaired with fiber glass filler.

I think this was all for this time. Hope the weather is with me tomorrow, so i can do the rest of my plans then.

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04-08-2011, 02:07 PM

ZyNTeX

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By the way. For some days ago i bough a new Sierrra DOHC. This car is in verry good condition, but i think i just want to use parts from it on this car.

I will take of all the parts from it and replace them on my car after i have painted them.
When it comes to the driveline i will be painting it black and mount the new polyrace bushings from rallydesign. I don't have all of it yet, but i will order the rest of this kit before they get on this car.

Is it anyone of you who can recommend a company for me who sells coilover kit to my car? All proposals are recieved with thanks!

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04-08-2011, 02:40 PM

gouch1

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quality

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04-08-2011, 03:02 PM

R4N SS

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if the new car is better why not use that instead?

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04-08-2011, 04:06 PM

ZyNTeX

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Quote:

Originally Posted by gouch1

quality

Thank you

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04-08-2011, 04:08 PM

ZyNTeX

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Quote:

Originally Posted by R4N S S

if the new car is better why not use that instead?

Its not better than this one, also there are a lot of debt on it. The old owner haven't pay annual fee about four years. That's why i will use parts from it instead.

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04-08-2011, 07:00 PM

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Nice to see a non cossy Sierra getting some attention. With a ported and polished head and some cams I doubt it made 180bhp. I been messing around with these engines for years and the only way to get that power from them is to fit a turbo. The upper limit for a non turbo is about 150bhp, and that's having everything possible done to it. They do however, have good low down torque. If you can get an engine loom from a car with a cat, or if you already have one, you can fit the injectors from a Vauxhall 2.5 V6, which are much better and can cope with other upgrades you want to do to the engine. Good luck with it, keep us posted

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04-08-2011, 09:24 PM

#11

ZyNTeX

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Quote:

Originally Posted by Marcyg

If you can get an engine loom from a car with a cat, or if you already have one, you can fit the injectors from a Vauxhall 2.5 V6, which are much better and can cope with other upgrades you want to do to the engine

Hi there. Now i'm not actualy sure what you meen. Can i use injectors from Vauxhall 2.5 V6 on the original Ford air intake manifold?
In Norway we use the German word for Vauxhall (Opel) I think it's some few cosmetic shanges between Opel and Vauxhall, but the engine is probably the same

If you say 150bhp, it's probably what i have in this car. (With original ECU)

Maybe i ask you some questions if there is something i wonder about, if it's okay for you?

Yes, i will update you people as soon as it happend things here.

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04-08-2011, 10:49 PM

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ZyNTeX

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After i have been posting here i was out and weld the plate i missing under the right taillight. This is not finish and not so very good. This was the first time i try to weld in so thin aluminum and it was just so i can try to use the car this weekend if everything is going as i think.

On Saturday i will get the catalystic for my other car, so then i can cut of the flanges and weld it to a exhoust pipe.

Pictures are comming later, because now the clock is 00.45 so it's dark outside. Im not sure if it is AM or PM now, but the clock is nearly 01.00
It will be fine if everyone can tell me this. Is AM in the middle of day og night?

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05-08-2011, 12:11 PM

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keep the project going! lot of work there!

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05-08-2011, 01:46 PM

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Quote:

Originally Posted by Portugal

keep the project going! lot of work there!

Ofcourse! Today i'il gonna buy some parts so i can do something more when the weather is better. Now it's raining bad much. I'il think God has tapped the ocean and drop it over this town i live in :P

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05-08-2011, 02:09 PM

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R4N SS

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AM is morning/day
PM is afternoon/evening/night

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05-08-2011, 02:10 PM

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ZyNTeX

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Quote:

Originally Posted by R4N S S

AM is morning/day
PM is afternoon/evening/night

Thanks!

Then i learn a new thing today.

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05-08-2011, 04:39 PM

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It looks like this sierra has had a really hard life.It looks like it might take yoi a lot of work to getting it looking nice again.

Does your engine idle ok without the idle speed control valve not been in the intake pipe.I know when i fitted a cone air filter i got another intake pipe with the idle valve in and cut that down for the cone air filter to fit properly and for the engine to idle properly.

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05-08-2011, 05:37 PM

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Quote:

Originally Posted by ZyNTeX

Ask away mate, if I can help I will. By Vauxhall, I mean Opel for you. The Calibra or Omega 2.5 V6 injectors are the ones you want. They're top feed and fit straight into the Sierra fuel rail. Only thing you need to watch for, is the injectors sit in a plastic housing, these normally crack or split when they get old, you'll need to replace them or you'll be leaking fuel.

@Glen. You can get them to idle like that. There's an idle speed control screw on the throttle body and you can wind that in or out to get the desired idle speed. Only problem is as the valve isn't conntected, things like power steering could stall the car when stationary as the ecu don't know how much to compensate it by. And if the valve itself is unblocked, you'll be pulling in unfiltered air. I think K&N make an adaptor plate for it so it bolts on right next to the throttle body and you can do away with the intake pipe altogether and bolt the filter direct to the adaptor plate

Last edited by Marcyg; 05-08-2011 at 05:39 PM.

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05-08-2011, 06:12 PM

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Quote:

Originally Posted by Glenn.

Hi there.

Yes, this car has lived a hard life before i bought it. it has remained surprisingly good. I am on my good way to get a nice Ford again, and i will build it up to a good gooking car again

I have some problems with the idle on this car, but i have been told that this is because the map sensor is not mounted right. I'm not sure if that is true. On my other car it's sitting original air intake filter with charcoal, so i can try this one to so i can eliminate problems. There has not being any problems before with the idle, so it is an option to why it's going as it do.

I will pick ut some parts tonight or tomorrow, so i can try it then

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05-08-2011, 06:27 PM

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ZyNTeX

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Quote:

Originally Posted by Marcyg

Ask away mate, if I can help I will.

Ah, good. I will use you for help to things i wonder about. This is my first Ford and i have never skrew on that type of car. Only Audi, Bmw, Honda, Opel, Volvo, 4x4 cars and other, so this is very exciting

Quote:

Originally Posted by Marcyg

By Vauxhall, I mean Opel for you. The Calibra or Omega 2.5 V6 injectors are the ones you want.

Calibra 8v or 16v?

Quote:

Originally Posted by Marcyg

They're top feed and fit straight into the Sierra fuel rail.

Thats good

Quote:

Originally Posted by Marcyg

Only thing you need to watch for, is the injectors sit in a plastic housing, these normally crack or split when they get old, you'll need to replace them or you'll be leaking fuel.

This is often standard procedure on all cars with injectors. On my Audi 80 2.3 quattro i don't had to replace them. Thank god for that. This was expesive parts. Audi=Mafia business.

Quote:

Originally Posted by Marcyg

@Glen. You can get them to idle like that. There's an idle speed control screw on the throttle body and you can wind that in or out to get the desired idle speed. Only problem is as the valve isn't conntected, things like power steering could stall the car when stationary as the ecu don't know how much to compensate it by. And if the valve itself is unblocked, you'll be pulling in unfiltered air.

Do you have a picture of where this skrew i sitting?

Quote:

Originally Posted by Marcyg

I think K&N make an adaptor plate for it so it bolts on right next to the throttle body and you can do away with the intake pipe altogether and bolt the filter direct to the adaptor plate

Do you have a web site where i can buy this kit? What i have now is "home made style" for a better look than original. But i'm not satisfied with it.

BTW: I can see if i have a picture where you see how i have set vacuum tubes from the map sensor, so you can see if this is right or not.

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05-08-2011, 06:35 PM

#21

ZyNTeX

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New parts in stock now.
Fiber glass filler, sand paper for wet sanding. (For use on my rims before painting. They will be white.) Sanding disc for angle grinder, White and matte black paint. Black paint for the thrunk, roof and hood. 5mm spacers. I'm not sure if that is enough, but i'il try. If this isn't i will buy 2 more in same thickness tomorrow.

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06-08-2011, 08:18 PM

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ow i finaly get the catalystic from my other Sierra.
The clock is 10:04 PM now and the rain is comming. Damn, i hate this weather!

I could just let the catalystic stand, so i had to do something. The flanges was not there, because they was so rusty. A friend of me has a lot of them, so he could come with some new to me later.

Now is my catalystic empty! Content looks like charcoal, so if anyone will buy it, please feel free to PM me. Then you can ask your friends over to barbecue

They will never know what you use, and it probably the last time you treats food for them

How it's look inside.

Barbecue time!

BTW: If there is some words i write wrong, please tell me about it and let me know how i write it. The same if there are sentences i can write differend. Somethimes i had to use Google Translate for some words i am unsure of, and the grammar there is not the best. I will not be angry, because i want to be better in english than i allready are.

Thank you people for all help.

Stay tuned...

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06-08-2011, 08:21 PM

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ZyNTeX

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Edit: I try to get longer wheel bolts, since i use spacers, but there is no one who can't find some to me. Do anyone of you know if there is an other car i can use bolts from, who is longer than 46mm who is original on Sierra?

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07-08-2011, 02:30 AM

#24

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Is it anyone who have coilovers for sale? PM me with info and prices. Must have German TÛV...

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07-08-2011, 03:19 AM

#25

botters

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http://cgi.ebay.co.uk/ws/eBayISAPI.d...=STRK:MEWAX:IT

link for the wheel bolts

nice project, and your english is better than some of the english people on here

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07-08-2011, 06:52 AM

#26

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I've a DOHC as a daily driver. Very reliable and undestroyable engine. Love it.
Btw. nice project!

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07-08-2011, 08:09 AM

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Quote:

Originally Posted by botters

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=370456057716&ssPageNam e=STRK:MEWAX:IT

link for the wheel bolts

Thank you so much

An order is allready placed

Quote:

Originally Posted by botters

nice project, and your english is better than some of the english people on here

It's good to heer that my english is good enough and you understand me.

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07-08-2011, 08:14 AM

#28

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Quote:

Originally Posted by Cossiemainful

I've a DOHC as a daily driver. Very reliable and undestroyable engine. Love it.
Btw. nice project!

This is my first one, so it's funny to see what i can do without putting it away to a workshop.

I get the interest for cars for about five years ago, so there is still much to learn, especially since i skrew on much differend cars

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07-08-2011, 12:13 PM

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Then i've been outside and doing some work again. But now again the rain is over me. I just hate that f***ing norwegian weather! When the summer finaly is here, it's just raining. How about some sun for just one day?

Back to topic. I have now taken of the rear fender, so it's now ready for a replacement. I think i will wait to Monday (Tomorrow), so i can buy some paint and get the same color once, insteof of driving around in a blue car with one white fender.

I may be wrong, but i think the car is looking like something who belongs at the scrap yard when it's many differend colors whitout a reason.

Todays work:

I'il had to split the fender, so i can se how it's sitting.

Is this legal widening of the wheelbow? :P BTW: Nice feets? :P

Halfway now!

As you see, it has allready start raining. Lokk at the inner fender, and you will see it.

You wouldn't belive it, but this little piece weighs less than 5 kg.

This is the front part of my old fender.

Hope you like my work, although I am self taught in automotive.

Stay tuned people....

Last edited by ZyNTeX; 07-08-2011 at 12:26 PM. Reason: typos in several places.

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08-08-2011, 11:35 AM

#30

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Yes yes, now we're talking. The sun i shining and i am out and do everything clear for painting while i listen to good music. Volbeat, Marilyn Manson, Guns'n Roses and Dire Straits!

The fender is washed and ready for some paint. Looking forward to see how it will be. The new paint is probably a little lighter, but i don't think we gonna see that now. In Winter i will be repainting the car, so it dosen't matter so much...

BTW: Here is a film i make about how to light your sigarette without lighter :P

http://www.youtube.com/watch?v=HboIvfDWtSw

Enjoy...

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11-08-2011, 10:16 PM

#31

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Hello people. Today i had a very bad day, so what i have done today hav been going wrong. I tried tro weld my exhoust, but i do something wrong here. Before i use the brain and think how i should do it, i weld the downpipe and catalystic together. The results vere not good. The catalystic vere welded upside down, so the turn was pointing in wrong direction. Also, not over to the passenger (right) side, but the left side. It was then one thibg to do. Skrew down the downpipe, cut of the catalystic, turn it around and weld it together. Yeah yeah, easy to do, but not without more welding wire. I have to boy some more, but my pocket say "NO!" until Monday.

But i can begin to fix other things until then, so i am one step closer to get my license plates

Marcyg@ I have some problem with this car. It's about how much fuel it use. Could it have something with my map sensor og crank to do? I'm not sure if everything here is mounted right. I can see if i can find some pics and show you how i done it now.
I'm note sure if my crank sensor are giving right impulses or not. How can i find out of this? I use about 5liter fuel on 10km, and this could not be right.

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26-08-2011, 08:37 PM

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No interrest for my project? It's very quiet here.

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26-08-2011, 08:44 PM

#33

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BTW: My rims will be painted tomorrow. A friend of me had tire overlap machine, and i can use it for free.

In the meantime i bought one another sierra dohc. It was it was supposed to use it for parts, but many of my friends say "NO!" It was in to good shape for that, so i have to rebuilt this one to. I wonder what i shall do with so much cars, because now i have 1 Audi, 1 Bmw, 2 Sierra's and maybe one Mercedes E3oo W124 with facelift parts. I don't have enough money to get all of them on the road at the same time.

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