HirenRS

hi there just after a bit of advice here,

just finished rebuilding my zetec turbo gave it a little refresh, bearings, rings, new botom end gaskets etc,

since putting it back together it hesitates badly, i have replaced edie module, tps, coil pack, spark plugs, in a attempt to sort it but it wont have it it drives under 2500 pm okay ad nythinpast the 3000 rpm its fine, timing is spot on i re-checked it using a dial gauge and was able to lock the cams exaclty at top dead centre, the car has been put back together the same as it was when removed and i never had this problem previously its runnig on ofab management wih cossie green injectors i have a chip suited to zetec but car has same problem regardless of chip being connected or not,

anyone experienced this kind of problem?

i can say that the hesitation comes on as the turbo is spooling, if i am extremely gentle on the accelerator and build u prefs slowly or drop gear and pin it to get it pas 2500 rpm it runs through the rest of the rev scale just fine currentlycruising at 30mph is hard and pulling off in first is worse.

also i hae noticed a slight tap at low rpm sound slie its coming from the top of the engine, possibly a lifter, its currently running mineral ol as advised by my engine builder to help bed the new rings, anyone else had a noisy tappet on a silvertop before?

silvertop zetec
decomp plate
cossie greens
ofab ecu

gingerturbo

iTrader: (2)

Are the plugs gapped and are the valves seated properly

HirenRS

i stuck somenew plugs in it today focus rs 2.5l, they came gapped and were checked anyway, made no difference in running o the car, also the head was completely re-built ported and polished before i was removed from the bay, it had only covered 600 miles until a piston failed and was stored as it came off with all manifolds still intact,

the car idles well and doesnt smoke etc, seems to rev up freeish apart from a bit of a glitch around the 2000 to 3000 rpm window, sometimes when on idle and i press the accelerator the car bogs out then revs rise and then hesitate againg at around 2500 ish rpm, took it out for a spin today and the tap does not get louder with rpm, when on boost pulls lovely, currently on low boost 7 psi,

parts changed today to try and rectify problem,
spark plugs
coil pack
edis module-back o original now as it made no difference
fluid levels checked
timing checked with dal gauge and cams lock when cylinder 1 hits tdc.

the batter is fine it has enough cranking voltage and the car starts o the key idles well with iscv connected, an sits smoothly at about 800-900 rpm when disconnected, doesnt hunt or race on idle

frsjon

not sure on the problem but cossie greens wont work on ofab? wrong impedance ?

HirenRS

im sure they are cossie greens, i have a prt number i will fetch it now, i know that the last time i probed this car under load using a innovate wideband there was sufficient fuel running slightly rich and better without the chip plugged in :/

HirenRS

02801 150 743

HirenRS

<a href="http://s1076.photobucket.com/user/HirenRS/media/IMG_2311.jpg.html" target="_blank"><img src="http://i1076.photobucket.com/albums/w456/HirenRS/IMG_2311.jpg" border="0" alt=" photo IMG_2311.jpg"/></a>http://i1076.photobucket.com/albums/..._2311.jpg.html


also the valves were machined with three angle valve seats also machcine matche to the valve seats lapped and grinded the head was previously also pressure tested etc, the hesitation has been there since assembling the car the slight tap im getting is a recent thing but i am led to believe this could be a lazy lifter i had the cam cover off today whilst ill dialed tdc and looked for any obvious sigs and spotted nothing obvious, no excess ear on cam lobes and all caps secure, engine turns freely by hand, the ca has only been on for a few days since re-build,

the act sensor i have is correct could the way the wires are attached to it cause problems, the wire was cut and extended so if the wires are not matched would this affect function of the señsor?

also,

people say co pot failre can cause fuelling issues can these be similar to mine?

the engine so far has covered 50 miles


got som injector data too

type-ev1
resitance ohms-15.9
test medium-heptan
operating pressure-300
qstat at operating pressure (g/min)

bosch injector-02801 150 743

gingerturbo

iTrader: (2)

We're the plugs wet ish or burning nicely, also is the throttle body/cable getting stuck

HirenRS

na nothing wrong with plugs m8 came out dr and showing signs of good burn, i have today replaced the injectors and chip and the car seems to run beautiful, its now on beiges and a chip which is supposedly suited i will have to get it on the rollers over the wekend just to make sure everything is all good, but is rnning nicely, currently not muh load on engine as i am bedding it and the tapping noise i mentioned got a little louder and turned out to be exhaust manifold gasket! so shes all good for the time being....

anyone running beiges on 2.0 zetec turbo?

gingerturbo

iTrader: (2)

We're you having a lot of issues with the greens then as in building a 2.1 zetec turbo and the cvh/zvh I've done have always run beiges, it must be the way they deliver the fuel

frsjon

what car are the 'greens' off of? there not ones used on cossie as the last of the part number would be 803 and yours look more like blue than green? do you know what cc they are?

HirenRS

its on beiges now and runs sweet, it was stil however hesitating and after changing the fuel pump from a escort cosworth one to a stock and a new earth on the engine seems to have cured it completely, also replaced the fse fuel pressure regulator for a stock ford

i do have question regarding management, anyone using ofab to run zetec turbo and if so what chips are you running?

spec as follows
beige injectors
airtec cooled water and air
t3 escort turbo
fiesta rs turbo inlet manifold
arp big end bolts
arp flywheel bolts
port and polished head stock cams etc..

if all else fails i have a emerald ecu lined up just need to find out if its going to be compatible

as far as the greens go i think they were off a sierra 2.0 from what i have read,

robp-tt

iTrader: (1)

I use to run ofab on mine, had a chip and injector kit from area six for a zetec turbo, I wouldnt drive it too hard with the injector and chip setup you have because its only fueling for a 1.6 not a 2.0,

HirenRS

i will have a look into it, im not planning to drive it hard for a while anyway still bedding the engine so will be a while till it sees any abuse, took it back out to university today and it drives lke a dream now cant put my finger on exaclty what was causig it but either a bad pump, or a faulty earth from engine to body,

anyone selling any suited chips?

HirenRS

took my car to the dyno yesterday for a safety check to see how it performed under load, didnt get to complete it as it was detonating and air fuel ratios were around the 13, i was concerned with the detonation and lean running of car and asked the tester to stop!,

i now need a management solution anyone used boost monkey's ofam? apparently runs a ms2 board so its got to be a winner?....

other than that i have a emerald ecu lined up but not a clue what spec it is, it was run on a 20vt vw which has independant coils unlike the zetec so not sure if it has the compatibility for zetec and it requires a looom being made up

or a dastek unichip piggybank on a loom to fit ofab but how good arethese?

luke19790_3

Easy option would be ofam, plugs into the loom you have now

also change those injectors they are too small

Maxwell

Get an omex 600!!

luke19790_3

Why?

Maxwell

Why not? He said he wanted management solution.

Paying cheap, only leads to paying twice. He already has a chip and is now having to pay again to sort out his management. So buying decent management to begin with is the only way forward in my opinion!

HirenRS

okay i have sorted a emerald m3d ecu and have ordered a part built loom from emerald along with a base map, i will be getting larger injectors once i have bedded the engine, i beleive i should be okay for low power for a while, i will be self mapping this aswell have got a software ready installed!

the next step is to remove all ofab loom and ecu along with edis co pot and map sensor nd possibly use on my 90spec cabby which is 8v cvh turbo or sell it !

anyone running emerald m3d on a a zt?

luke19790_3

What boost you running ?

luke19790_3

Do you have a wideband lambda fitted

HirenRS

i dont have a wideband lambda fitted as of yet, i am going to weld a boss on in the next few days will keep pictures coming, i also have acsess to a innovate wideband lambda which a friend uses to set up his cars,

the next question is which lambda sensor do i use heated or normal?

boost currently set at the wastegate @ 9psi...for now hopefully

HirenRS

you reckon the emerald will do me suffice the specs seem quiet good

Maxwell

Yeah an Emerald is perfectly capable of the job. They are used frequently on turbo saxo and 106s. And their owners are more than happy with them and the results and reliablility they have when using them!!

Omex600s are used alot on them too, hence me advising one. Also, alot of Ford turbo owners use an omex600.

HirenRS

sweet im going to try nd get permission to use the dyno at my university sun 4wd thing :/...to map it, next thing to get on with is making detcans

rsmark86

iTrader: (3)

i got a innovate lc-1 with led display for sale ??

can keep an eye on it, i have the same set up as you

rebuilt zetec with calibra turbo pistons ect
stage 1 t3 rst turbo
head rethreaded to fit cvh exhaust manifold
ho inlet
green 803s
ofab with zetec chip
grs cooler
and so on

only problem i have is the injectors are ticking pretty loud and im guessing thats down to them being the wrong injector for the ecu so im going to get the ofam fitted and mapped by boost monkeys soon

for the sack of £650 it can be set up perfect for the spec, and the standard ecu is worth £100 anyway