Continued, Last big uptodate-update...

Bought a few goodies on tuesday consisting of...

Jenvey 45mm Throttle Bodies
45x45mm trumpets
Jenvey throttle linkage and Fuel rail
Bosch 330cc injectors

Should be here tmoz with abit of luck...

as the bodies are off a Puma 1.7SE, ive bought them off him minus the inlet manifold... so ive contacted Jon @ Shawspeed about a Jenvey inlet manifold, he ordered one yesturday, should be here for the weekend with abit of luck then Jon is going to drill and tap it for the Brake servo vacuum for me. You can get DCOE inlet mnaifolds off ebay for cheaper than the jenveys but the jenvey ones keep the same angle as the Port iteslf rather than upright then the bodies pointing directly horizontal so with the jenvey manifold they should have a really nice angle just like the DTH jenveys i had on my ZS

With going down the fuel injection route, im needing to change the Fuel tank, Fuel pump and Fuel pressure regulator too...

I Bought a brand new Mk2 Injection fuel tank yesturday that should be here within the next few days too...

A friend is going to be the brains of this conversion really, Im buying his Omex 600 off him and for that hes going to be sorting me a Engine bay loom too wirirng it all together at his house then just come to mine with it on the day and we'll simply plug it all in and hopefully itll fire up, obvioulsy once the bodies are one, fuel tank etc etc are all plumbed in. Also im having a ERST fuel pump and a FSE regulator too off him which are 2 of alot of random parts andy owns lying around lol

Just taken the carbs, manifold, regulator and fuel pump off -



Manifold arrived thursday, join drilled and tapped it for me and here it is fitted -



brake servo vacuum -



tank arrived friday -



Painted the fittings on the oil cooler to make it look more stealthy -



removed the sound proofing from under the bonnet and cleaned it up -



Got a new fuel filter yesturday, the narrowest one i could find and which was an inline one and had 8mm in/outlets, meant for a 106 xsi lol -



Bodies etc arrived Monday night



... so tuesday i cleaned them all up, worked out how the linkage goes and took the trumpets off ready to fit them... then tuesday, fitted them, mounted the boides then fiddled with the throttle cable and pedal till the butterfyls were perfectly level...

after bending the stopoer bracket on the throttle pedal -



i got this -



then re-fitted the trumpets -





Cant wait to hear them

Fuel tank painted now, had 2 coats of smooth hammerite -



mega progress.........

saturday -

started work on it at 12pm, finished at 8pm, this is what we got done.....


Old tank off (hi andy) -



New tank and fuel pump all fitted after about an hours fiddling -





Filter plumbed in and mounted lol -



FSE fuel pressure regulator (power b0000000st valve) mounted -



then finished plumbing all the lines etc, then put 18litres of tesco 99octane in...

then onto the wiring only pic ive got of any of the wiring -



then finished all the wiring, swapping the pins over onto the omex 200 plug, wired up the fuel pump, conected the battery, fuel pump primed for 2 seonds when turning the keyonto stage 2...

took the key out about 15-20 seconds later we spot smoke pouring out from inside the car... turned out to be this -



all the plastic casing/coating on the wire right from the battery to the fuel pump relay (which is behind my drivers seat and the battery is in the engine bay still) was all like this and burnt off/melted.

with having no more wire and it dark we had to call it a day specially as my internet couldnt get a decent enough connection to download the omex software onto a mates lap top...

ALSO noticed, fuel pissing out all down the side of the front of the tank, looks like ts coming form where i blanked off the existsing lines where they come out the top where you can see n the forst picture, so tank and pump, drain the fuel all again

sunday -

what another day lol............


Went to halfords got 5m of 27amp wire and a fuse holder for the 12v feed for the fuel pump relay, and a new 35-40amp relay which cost a fiver LOL...

got back then andy came we wired the fuel pump etc back up first, i jumped underneath to connect the connections only to notice i wired it up backwards, no wonder it burnt ...

connected the battery and wahey we have a fuel pump that primes spot on and a wire that doesnt set on fire

then tried to link 3 different laptops upto the ECU, all 3 were having none of it, so off to maplin to get a new USB-serial cable... tried that, still no joy...

then tried a direct earth from the omex to the battery and wahey, Brens majic laptop liked to talk to my Omex 600, then after a few touches to the map from andy he truned the key, after lots of Pops/bangs and flames from out the bodies, it wouldnt come to life, went throgh every wire and sensor on the loom, turned out when we swapped the wires on the coil pack (no idea why they are different to the omex 200 as every other wire is exactly the same on the plug)... it livvvedd, not very well but it came to life for about 20seconds...

Also checked the tank when it the car was running and no leaks, so must be leaking from the filler neck, so tank still has to come off etc, sigh

heres the engine bay completed and a new addition -









so as soon as andy can when he comes back to mine, we need to swap the pins over on the coil pack again after bodgeing it up with a spare connector, sort a new earth out for the omex, then go from there hopefully it runs, can mapp it so itll drive nice enough till i can get to Mikeanics, then get the tank down and see where the leaks coming from.


Monday -

Andy came round about 12ish, swapped the pins over on the omex plug for the coil pack, new earth and ignition live to the omex too...

then tried to connect the laptop upto the ECU, still wasnt connectong for some reason ... then tried everything, then went to maplin to get a serial to serial cable and took the car battery, omex and my spare loom in the house to try link it all to my computer and great success! it worked, so then andy sorted all the settings on the omex, took it outside car seemed to run a little better, then took my computer outside, fired in the lambda sensor in the exhaust and begin mapping lol -



did it once took it for a spin, then back again to adjust the fuelling, back out again, then back to adjust the fuelling, then back out again, andy is happy hows its at now, he also took a litle vid which im sure he'll post up when he gets a minute, its still quite rich upto 2k but sweet after that...



And had it mapped yesturday heres the results -






exactly what i expected tbh, and the drive of the car is sooooo much nicer/better now, rediculously smooth and the sound is fkin epic

Problems of the day were...

throttle linkage seperated on the way there and on the way back, so just got a m6 niut to sort that so hopefully no more problems there now and also set the idle to 850rpm.

also noticed the fuel dripping out as it were being mapped like constatly dripping from a few different areas, think its the sender seal on the top of the tank so job for saturday is to drop the tank and see whats what, sigh! so tank off tomorrow job

also just started the car to see how the map is from cold, started without even having to press the throttle at all and after 1min of running its spot on just a little boggy for the first minute nothing major or nowhere near as bad as the carbs were


Current Engine and Transmision spec -

2.0 Zetec E s2 silvertop
Baffled 1800 Sump
Omex 600 Management Mapped by Mikeanics, 175bhp & 143 lbs ft.
Jenvey 45mm throttle bodies with 45x45mm trumpets
Jenvey inlet manifold
Bosch 330cc injectors
ERST fuel pump
FSE fuel pressure regulator
Ashley Heatwrapped Modified 4-2-1 manifold
Ashley 2" single box system with added in flexi joint and custom 2.25" tip
NGK Platinum Spark plugs
Modified Zetec & CVH coolant hoses
Mk3 Zetec radiator
Mocal 13-row Oil cooler with thermostatic sandwich plate
Mocal Catch tank
Lightened & Balanced 1800 flywheel
Helix organic clutch
FRST ratio'd Mk3.5 Si gearbox
XR2i Starter motor


Sorted the tank leak, was the seal on the top on the sender, was a faff after getting fuel in my eyes and hair but got their int he end and no more leaks and after going out for a drive init tnite i must've avereaged 30mpg over the whole journey of very mixed driving which im pleased with...

Heres a couple of Drive by vids for y'all -

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

http://www.youtube.com/watch?v=2GC1xwz2Tk0

http://www.youtube.com/watch?v=XZD3ZDgOLQg

First ones my fave as thats the best spound quality off my mates phone, the other 2 are off my camera, still sounds ace tho


So there we are after nearly 6 months


Ideally could do with a new throttle cable as its sticky quite badly atm and its not nice when your at high speeds and you lift off and your car carries on lol, will get one ordered very soon...

going to re-paint undere the tant tmoz after where all the paints came off where the fuel was leaking too.


Hope you like