300hp fiesta 1.6tdci project
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300hp fiesta 1.6tdci project
i've used this site for a few years, i used to be known as turboboss and played about with a red frst but due to buying house i broke my frst for the deposit, then when things had settled down a bit finance wise purchase i bought a fiesta zetec s 1.6tdci just because it was cheap to run with only £30 a year road tax.
i started to do some mods remap, exhaust then i wanted to go a bit further well more then just a bit most bit have been through trial and error so far upgrades focus 110hp injectors, turbo dynamics kp35 hybrid turbo,ss exhaust from turbo back,fcd2 ( thanks stewart),FMIC, kevlar clutch, methanol injection kit and a rs tuning custom map giving me 156hp 260fbt.
focus 110hp njectors
kelvar clutch
FCD2
for my next incarnation
injectors modified with bmw 335d injector nozzles thanks dieselbob
you know how one thing leads to another i wanted bigger valves, but due to the lack of room between valve and bore wall this was not feasible, so my fabricator has been speaking to his engine shop its taken quite a bit of convincing of hwy we want to pursue tuning a 1.6 diesel but they have now come round to the idea and are fascinated about the project. 0.05mm oversize pistons are only available which is no use to me reason for this the engine comes with liners so a rebore is not possible. The engine shop state they have repair liners on the shelf which can take the bore from 75mm to 80mm increasing capacity from 1560 to 1775, but locating a set of pistons seams to be a tad difficult because of the small end, but i am just going to get farndon to make me a set of rods with a small end of my choice........Increasing the bore size allows a whole host of alternative valves sizes, best combination seams to be 26mm exhaust and 29mm inlet from standard 23.4 exhaust and 25.5 inlet so a gain of 23% and 29% respectively which is quite a lot, All the porting is done to a spare head I will put pictures up as soon as I can
I have been looking at the gearbox side of things without this the project wont start, now building a stronger Ib5 box is simple but building one with the right gear ratios is causing me headache the fiesta 1.6tdci comes with a 3.7 F/D with 205/40/17 tyres giving a rolling radius of 6.14 @ lets say 4800rpm gives a top speed of 113mph, there are two other F/D available which suit a diesel perfectly a 3.3 and a 3.1 the 3.3 comes with the same 8-bolt fixing as the 3.7 but good old fords for some reason decided to change the later fiesta 3.1 to an 12-bolt fixing 8mm screw and a totally different carrier, so I am waiting on a machine shop on a cost to see if the parts can be machined to fit
turbo GTB1756vk off an audi q7 3.0tdi good for 32 psi at 2000rpm new generation vnt want to go to a hybrid GTB2256vk at a later date
audi 2.7 tdi fuel pump and pressure sensor
ported head with larger valves
custom inlet manifold
straight through 2.5" exhaust system with no box
tubular manifold placing turbo over gearbox
i started to do some mods remap, exhaust then i wanted to go a bit further well more then just a bit most bit have been through trial and error so far upgrades focus 110hp injectors, turbo dynamics kp35 hybrid turbo,ss exhaust from turbo back,fcd2 ( thanks stewart),FMIC, kevlar clutch, methanol injection kit and a rs tuning custom map giving me 156hp 260fbt.
focus 110hp njectors
kelvar clutch
FCD2
for my next incarnation
injectors modified with bmw 335d injector nozzles thanks dieselbob
you know how one thing leads to another i wanted bigger valves, but due to the lack of room between valve and bore wall this was not feasible, so my fabricator has been speaking to his engine shop its taken quite a bit of convincing of hwy we want to pursue tuning a 1.6 diesel but they have now come round to the idea and are fascinated about the project. 0.05mm oversize pistons are only available which is no use to me reason for this the engine comes with liners so a rebore is not possible. The engine shop state they have repair liners on the shelf which can take the bore from 75mm to 80mm increasing capacity from 1560 to 1775, but locating a set of pistons seams to be a tad difficult because of the small end, but i am just going to get farndon to make me a set of rods with a small end of my choice........Increasing the bore size allows a whole host of alternative valves sizes, best combination seams to be 26mm exhaust and 29mm inlet from standard 23.4 exhaust and 25.5 inlet so a gain of 23% and 29% respectively which is quite a lot, All the porting is done to a spare head I will put pictures up as soon as I can
I have been looking at the gearbox side of things without this the project wont start, now building a stronger Ib5 box is simple but building one with the right gear ratios is causing me headache the fiesta 1.6tdci comes with a 3.7 F/D with 205/40/17 tyres giving a rolling radius of 6.14 @ lets say 4800rpm gives a top speed of 113mph, there are two other F/D available which suit a diesel perfectly a 3.3 and a 3.1 the 3.3 comes with the same 8-bolt fixing as the 3.7 but good old fords for some reason decided to change the later fiesta 3.1 to an 12-bolt fixing 8mm screw and a totally different carrier, so I am waiting on a machine shop on a cost to see if the parts can be machined to fit
turbo GTB1756vk off an audi q7 3.0tdi good for 32 psi at 2000rpm new generation vnt want to go to a hybrid GTB2256vk at a later date
audi 2.7 tdi fuel pump and pressure sensor
ported head with larger valves
custom inlet manifold
straight through 2.5" exhaust system with no box
tubular manifold placing turbo over gearbox
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Hi m8
I thought I'll start posting 0n this site again, having te gearbox built now, which I was going to do in te first place I hate te standard ratios
I thought I'll start posting 0n this site again, having te gearbox built now, which I was going to do in te first place I hate te standard ratios
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Hybrid. Set me back £1875 which includes te price of a new turbo, I requested turbo dynamics for te largest compressor and exhuast turbine which could fit in te fiesta kp35 turbo. Housing. They had to cnc fcd te 1.6 diesel engine will do 150hp with ease, this hybrid will be for sale soon at a good price because I am going bigger
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gearbox standard ratios are not good with a 3.7 C/W weak diff and fragile teeth not much use for big power or top speed, so i enlisted a transmission company called G.E.A.R.S tv to build me a box....................Specification is as follows
3.05 crown wheel & pinion
quaife ATB diff ,modified 12-bolt crown wheel to fit diff
shimmed diff to obtain correct preload
late high ratio gear set (3.15 1st gear) similar to rs turbo ratios
new bearings,syncro rings nub shifing plates and tension springs
cryogenic treated gear set
3.05 crown wheel & pinion
quaife ATB diff ,modified 12-bolt crown wheel to fit diff
shimmed diff to obtain correct preload
late high ratio gear set (3.15 1st gear) similar to rs turbo ratios
new bearings,syncro rings nub shifing plates and tension springs
cryogenic treated gear set
Last edited by Badman38; 31-08-2012 at 12:55 PM. Reason: wrong wording
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Car is nearing completion had a bit of trouble enabling the vnt control, still quite a few bits to do the turbo is a GTB1756 good for 240hp on a 1.9tdi but I will eventually have to go bigger, taken a long time but its still work in progress by station Motorsport.
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currently trying to find a suitable fuel pump the car comes with a 70cc pump good for 190hp attempting to make fit a 135cc pump which can supply enough fuel for 300hp, i want to ensure pump on working with larger nozzles before the mapping
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the focus injectors are the same size as the fiesta but supply more fuel, no coding neded.......... we thought they might need coding my mapper put them in writing down the codes for coding but he thought lets just try it" turned the key and the engine fired up
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larger pump fitted to dummy engine modifications to the bracket connecting the pump to the engine, remachined sprocket relocated tensioner, larger fuel feed pipe, pump being fitted today i am surpised at the size of the common rail high pressure compared to a the old mechanical pumps but even this pump is much larger then standard.
i have been waiting nearly two months for this pump from design to completed unit, wont take this long for the next person because all the development work been done i hope its worth the wait... this pump will work on both variants 90hp & 110hp
i have been waiting nearly two months for this pump from design to completed unit, wont take this long for the next person because all the development work been done i hope its worth the wait... this pump will work on both variants 90hp & 110hp
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Thanks ran I tried to leave her aloan but I am doing so much research in re dv6 engine te same engine in te mini, peugeot hdi, citreon hdi, volvo.... to make 300hp re engine will be far from standard re nozzles and fuel pump can exceed 300hp turbo wise I can either go gtb2265 which is a hybrid version of a turbo fitted to te audi q7 3.0tdi or te best of both worlds compound charge, but then te block would be in need if some serious strengthening to handle 70+psi and te high cylinder pressures that goes with it.
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Thanks ran I tried to leave her aloan but I am doing so much research in re dv6 engine te same engine in te mini, peugeot hdi, citreon hdi, volvo.... to make 300hp re engine will be far from standard re nozzles and fuel pump can exceed 300hp turbo wise I can either go gtb2265 which is a hybrid version of a turbo fitted to te audi q7 3.0tdi or te best of both worlds compound charge, but then te block would be in need if some serious strengthening to handle 70+psi and te high cylinder pressures that goes with it.
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In Portugal where they regularly race 1.6hdi there r a few over 200hp, but trying ti get any info is trying to get blood out of a stone so all te research is done by ourselves, what do u think will fail? Knowledge which I lack is a good thing
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Usually the rods go first, bolts are only torqued to about 20-30nm, but if you're changing them you'll hopefully avoid that issue.
Main bearings would be my other concern. The alignment of the bores isn't great and the bearings are slightly oval, mains are only done up to 40nm on m9 stretch bolts. The bottom end is very weak in general.
Only thing I'd say re the Portugal scene is the plumes of smoke they produce to make the power, I ran a 1.9tdi golf in Portugal spec once and I painted lines of pure spot on the floor
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Have you try to find a EP6t (mini cooper S and 207RC for ex.) , the bottom end are very similar , maybe crankshaft , rods are stronger for 200hp+ tdci
I have a question for you Badman, do you know the best way to drive a VNT Turbo on a fiesta , it's for me , I think to put a DV6 swap on my DV4 fiesta , and I want to have a reasonable 135-140hp with a 110hp Focus engine setup
I have a question for you Badman, do you know the best way to drive a VNT Turbo on a fiesta , it's for me , I think to put a DV6 swap on my DV4 fiesta , and I want to have a reasonable 135-140hp with a 110hp Focus engine setup
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Also I don't think there's room for 80mm liners. Standard liners are 3.5mm thick approx all the way round. Block thickness liner to water jacket is approx 4.5mm and liner to liner block (ie between cylinders) material is approx 2.5mm, so unless you liners are as thin as shit custard there's no room?
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Yes its been a long time I thought I'll try something different, bought a house which is why te fiesta had to go now i have a five month baby girl I purchased te car as it was cheap to run but u know how it goes from a basic remap to this..
Last edited by Badman38; 24-01-2013 at 01:13 PM. Reason: Wrong spelling
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Also I don't think there's room for 80mm liners. Standard liners are 3.5mm thick approx all the way round. Block thickness liner to water jacket is approx 4.5mm and liner to liner block (ie between cylinders) material is approx 2.5mm, so unless you liners are as thin as shit custard there's no room?
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Have you try to find a EP6t (mini cooper S and 207RC for ex.) , the bottom end are very similar , maybe crankshaft , rods are stronger for 200hp+ tdci
I have a question for you Badman, do you know the best way to drive a VNT Turbo on a fiesta , it's for me , I think to put a DV6 swap on my DV4 fiesta , and I want to have a reasonable 135-140hp with a 110hp Focus engine setup
I have a question for you Badman, do you know the best way to drive a VNT Turbo on a fiesta , it's for me , I think to put a DV6 swap on my DV4 fiesta , and I want to have a reasonable 135-140hp with a 110hp Focus engine setup
Last edited by Badman38; 24-01-2013 at 01:41 PM.
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Looking good chap
Question for you.
Which gearboxes carry a lower ratio final drive as i want to reduce my engine speed whilst cruising?
Question for you.
Which gearboxes carry a lower ratio final drive as i want to reduce my engine speed whilst cruising?
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i think the c/w came off a fusion but the gearbox carrier needs machining to fit due to the bolt pattern changing but i will find out for definate
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