Major hauling up of an old post here but thought I'd post my progress including the ups and downs since I posted this.

Once I had the intercooler fitted I had the car serviced ready to be sent off to Grove Garage for mapping.











Those pics were taken once I got it back

That very night as I let off from high boost the inlet manifold decided to blast one of the bolts out causing a major air-leak, so I had to wait another few days before driving it again once I'd sorted out machining a new thread and putting a new bolt in.

(the right hand hole in the picture below)



I also purchased a silicon reducer pipe to fit from the standard charge carrier to the modified Cossie throttle body (mounted on it's side)



Shortly after getting the inlet manifold/throttle body leak plugged I then started having major major problems with the ECU on my car.

As I was driving the car back from a test run the car started misfiring and then when driving it about 200 yards from my house the ECU cut out completely meaning I had to push it the final bit home!

Everything was checked over, I went back to Grove Garage with my ECU and ignition amplifier to check and see if it was that but to no avail (I even bought another L8 ECU and swapped the Pectel board across to see if it was that) but still I was having major problems. A friend of mine Andy B from fiestaturbo.com came down and helped me out big time with trying to source the fault but all seemed ok on the ignition side.

As we'd eliminated all of the easy stuff I then had to remove the engine loom completely and check it all over with a multimeter (I even put up a post on here which helped me alot - some really clever people who use this site! ) and check for continuity through all the terminals to each of the sensor plugs.

Strangely this all checked out (apart from a very manky looking cam sensor plug) so I replaced what was broken and put it all back in.

During the investigation throughout the engine wiring we also found that the CPS was completely free-moving and not held in place. The Cossie management conversion I'm using makes use of a 1.8CVH Sierra CPS as this gives the same waveform (Weber Marelli) as the standard Cossie CPS (although my signal comes from an adapter disc on the crank pulley). I then had to get this fixed which took quite some doing due to the lack of space between the bracket and the chassis leg in the Fiesta engine bay.

That was fixed and the car was running again - but I had a persistent problem where the car would start to misfire when the engine got warm. This problem would carry on up until very recently.

I tried various ways of fixing the problem which started with the obvious by making sure the ignition system was as good as possible.





I also got some thermotec heat sleeves for the ignition leads but I'm not really sure if they do much in stopping heat getting to them (they're mounted much more firmly over the spark plug ends now than in this pic).



Having changed all of that it still had this damn misfire!

Then another bad thing decided to happen - my AMAL valve managed to explode! With the way the AMAL valve was mounted it must have caused one of the hoses from the actuator to crack one of the ports on the AMAL valve causing the whole unit to crack into several pieces when passing boost. So I had to wait a week for Ford to special order in another one

Once all of this was sorted I then decided to have a crack at TOTB qualifying in the car - which was to see me encounter more problems on the way home!





I'd never done any quarter mile racing before so was pretty pleased with the times I was getting in - (14.6 or so at 99mph, down to 14.4 and 6.1 0-60 with 100+mph terminals at the end of the day) but I was being dogged by misfire problems after driving the car for a while throughout the day, which is when I met Jano Oddkidd.

He took a look at the setup on my car and pointed out that the cam-sensor would be what is causing all my issues. He then showed me the setup on his car which since fitting hasn't caused him any problems.



Unfortunately on the way home from the qualifying event I had another problem with the car, as I was giving it a bit of stick on a dual carriageway close to home I saw a plume of grey smoke coming out from the exhaust in my rear view I pulled over, opened the bonnet and the oil breather was sending out smoke vapour and the oil cap had popped off! Thinking that my piston rings had probably let go or similar I put the cap back on and nursed the car home leaving smoke signals behind me 'Ford owner on the go-slow'

I decided as the cam-sensor arrangement needed to be changed and I had another near EFI head sitting at home that I better check whether any damage had been done to the engine. Off came the head and it was apparent that the valve-train had been getting really hot with the valves being a quite strong reddy colour! Putting this down to the misfire and the car jumping into limp home mode when the cam-sensor moves off it's phase (flimsy bracket it was mounted on) I had the head rebuilt and a new headgasket put on along with the cam sensor bracket, laser cut phase disc and machined vernier pulley that I had sorted out for me in very quick time by Jano Oddkidd. All I needed to complete the change over of cam-sensor system was a standard Cossie CPS which I ordered from Motorsport Developments as they kept them in stock (it's a special order part from Ford - that's if they can even find it on their system!). That arrived in quick time so a big thanks to MSD as well

Anyway - here's my new cam sensor arrangement and the bits that are now done.



Having put all that effort into getting sorted we have now discovered that the turbo oil seals are knackered!

So I'm going to have to send off my turbo for a rebuild - all that misfiring meant that unburnt fuel was passing through the turbo and it had been getting extra hot, thinning the oil out and doing some damage obviously Hopefully I can get it sent to Turbo Technics or someone and get it back good as new

For that reason I'm not going to be on track at Ford Fair like I had planned, but I will hopefully be there with the car on the FordSport stand (if I make it!) so come over and say hello!

Cheers,

Andy