Fiesta Zetec-S - Throttle bodies.... 11JUN07 - PAGE 5.update
29-05-2007, 06:57 PM
#161
Fucking superstar........
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Originally Posted by YoungDan
Thanks Rab - Just need to use it now though 
Got some Toyo Proxes R888s on order from Martin (Reyland) and have some 6 point harnesses on their way..
I need to pull my finger out and get a cage though.
Got some Toyo Proxes R888s on order from Martin (Reyland) and have some 6 point harnesses on their way..
I need to pull my finger out and get a cage though.
Toyos will make a massive difference
As will the cage.
01-06-2007, 10:09 PM
#169
PassionFord Post Whore!!
Thread Starter
Uppppdaaaaaate!
Thursday 31st May / Friday 1st June 2007
Right! Time for the next edition of "Dan does TB!"
Plan of action was to clean up the head, give it another lick of paint, get the inlet and exhaust valves back in, along with uprated springs.. Why uprated springs? because at 7600rpm+ we need the valves to snap shut, as quickly as possible, reducing any risk of the piston crashing into the valve... If this happens? we're fucked. This shouldn't be the case though, with the uprated valve springs. You can feel a difference between the one, standard you can compress.. uprated, you can't!!! After this, we needed to mount the TPS (Throttle position sensor, basically tells the ECU under how much load the engine is) and start building up the fuel rail with the new injectors, which come from a Vauxhall engine (ooh err!) the C20XE... (also known as the red top - the engine all the corsa boys love!)
Picking up from last Sunday, the head needed a clean, and the valves cleaned up, along with the ports.
So started on thursday by removing the old gasket from the head, taking care not to scratch it, as this could cause problems with the new head gasket! Took my time, and it came up well... as you can see below,
Before
After
As you can see all the old gasket (the black rubbery thing on the top photo is the gasket) has been removed... and the ports a bit of a clean up with some thinners. Looks quite nice actually and as good as I'll get it without using a machine to clean it.
Next up was the valves... tighten them in a drill, and hold some sand paper near by!! Should help the air flow in and out a bit easier, but as soon as it's started the exhaust valves will be black again..
Some of the inlet valves, after a bit of a polishing...
Silver top, black top? We also discovered there was a difference in the valves, it seems Ph1 valves have a B printed on them, and ph2 a T. Seems the phase one valves are a little shorter, and the collets sit a little higher... We ripped out the ph1 valves and stuck two ph2 in, just to be sure we had all the right stuff.
Next up was lapping the valves, this basically means there is a good seal between the valve, and the port, which means good compression! As Jon said, the more you spend putting into the engine, the more you get out of it in the end... It's good I don't need to rush, so I can make sure everything is spot on, and then Jon can make sure everything is double spot on afterwards! Anyway, back to lapping the valves... I used a paste called "chemico" think of t-cut but with more grit in... This is placed around the underside of the valve, where it sits into the port, and the valve is spun round with a grinding stick to make sure there is a nice clean, and even surface on the port for the valve to seal and sit. I did this probably two times each port, to make sure everything was good... Each valve was checked to see that there was a thin grey line around the underside, where the paste had worked it's magic, and this was present on them all.. If there were bits missing? It means the valve is bent!
The magic paste!
And the magic stick!!!
Done! it was pretty time consuming, but I'm glad I've done it to the best of my ability!
Next up was putting the valves and the springs back in... the valves had a touch of grease on.. as when a seal is created things tend to stick! so a dab of grease should stop this happening.
Putting the valves, valve springs, and valve caps on was a PAIN. But it's done now, and I'm glad. Same process as removing them, except in reverse. Knocking collets off is easy, putting them back on, isn't! Especially with the springs being so hard, they tend to fling back with a lot of force, but luckily we only lost one collet in the process! Below shows the collet on a screwdriver ready to go on the valve... 2 collects per valve, then release the valve spring compressor, and voila! done.
Collet on screwdriver, waiting to find it's home!
16 valves, 16 springs, 16 spring caps, and 32 collets later we have....
One finished head. All needs doing now is the cam position sensor screwing back in, and then the cams in and shims "shimed" up.
We gave the head a bit of a jetwash to clean things up, and knocked a little bit of paint off, so gave it another going over with the paint.. and it looks like below...
Next we started building the fuel rail... Bit of oil on the o-rings so they slide into the fuel rail, and the throttle bodies... we didnt' connect the fuel rail as we've still got to messure lengths when they're fitting to the head.
As you can see on the photo below, the TPS sensor is connected to the left set of bodies.
And there we have this update. May be a little update tomorrow.
Thanks for reading!
Thursday 31st May / Friday 1st June 2007
Right! Time for the next edition of "Dan does TB!"
Plan of action was to clean up the head, give it another lick of paint, get the inlet and exhaust valves back in, along with uprated springs.. Why uprated springs? because at 7600rpm+ we need the valves to snap shut, as quickly as possible, reducing any risk of the piston crashing into the valve... If this happens? we're fucked. This shouldn't be the case though, with the uprated valve springs. You can feel a difference between the one, standard you can compress.. uprated, you can't!!! After this, we needed to mount the TPS (Throttle position sensor, basically tells the ECU under how much load the engine is) and start building up the fuel rail with the new injectors, which come from a Vauxhall engine (ooh err!) the C20XE... (also known as the red top - the engine all the corsa boys love!)
Picking up from last Sunday, the head needed a clean, and the valves cleaned up, along with the ports.
So started on thursday by removing the old gasket from the head, taking care not to scratch it, as this could cause problems with the new head gasket! Took my time, and it came up well... as you can see below,
Before
After
As you can see all the old gasket (the black rubbery thing on the top photo is the gasket) has been removed... and the ports a bit of a clean up with some thinners. Looks quite nice actually and as good as I'll get it without using a machine to clean it.
Next up was the valves... tighten them in a drill, and hold some sand paper near by!! Should help the air flow in and out a bit easier, but as soon as it's started the exhaust valves will be black again..
Some of the inlet valves, after a bit of a polishing...
Silver top, black top? We also discovered there was a difference in the valves, it seems Ph1 valves have a B printed on them, and ph2 a T. Seems the phase one valves are a little shorter, and the collets sit a little higher... We ripped out the ph1 valves and stuck two ph2 in, just to be sure we had all the right stuff.
Next up was lapping the valves, this basically means there is a good seal between the valve, and the port, which means good compression! As Jon said, the more you spend putting into the engine, the more you get out of it in the end... It's good I don't need to rush, so I can make sure everything is spot on, and then Jon can make sure everything is double spot on afterwards! Anyway, back to lapping the valves... I used a paste called "chemico" think of t-cut but with more grit in... This is placed around the underside of the valve, where it sits into the port, and the valve is spun round with a grinding stick to make sure there is a nice clean, and even surface on the port for the valve to seal and sit. I did this probably two times each port, to make sure everything was good... Each valve was checked to see that there was a thin grey line around the underside, where the paste had worked it's magic, and this was present on them all.. If there were bits missing? It means the valve is bent!
The magic paste!
And the magic stick!!!
Done! it was pretty time consuming, but I'm glad I've done it to the best of my ability!
Next up was putting the valves and the springs back in... the valves had a touch of grease on.. as when a seal is created things tend to stick! so a dab of grease should stop this happening.
Putting the valves, valve springs, and valve caps on was a PAIN. But it's done now, and I'm glad. Same process as removing them, except in reverse. Knocking collets off is easy, putting them back on, isn't! Especially with the springs being so hard, they tend to fling back with a lot of force, but luckily we only lost one collet in the process! Below shows the collet on a screwdriver ready to go on the valve... 2 collects per valve, then release the valve spring compressor, and voila! done.
Collet on screwdriver, waiting to find it's home!
16 valves, 16 springs, 16 spring caps, and 32 collets later we have....
One finished head. All needs doing now is the cam position sensor screwing back in, and then the cams in and shims "shimed" up.
We gave the head a bit of a jetwash to clean things up, and knocked a little bit of paint off, so gave it another going over with the paint.. and it looks like below...
Next we started building the fuel rail... Bit of oil on the o-rings so they slide into the fuel rail, and the throttle bodies... we didnt' connect the fuel rail as we've still got to messure lengths when they're fitting to the head.
As you can see on the photo below, the TPS sensor is connected to the left set of bodies.
And there we have this update. May be a little update tomorrow.
Thanks for reading!
02-06-2007, 10:56 AM
#174
PassionFord Post Whore!!
Thread Starter
I can see how he gets angry and fed up with it, it's fucking time consuming and I got pissed off well bad a few times
The wiring is what I'm dreading though.
I'll find you a carpark and you can take it for a spin
The wiring is what I'm dreading though.
I'll find you a carpark and you can take it for a spin
02-06-2007, 03:02 PM
#178
Excellent write up Youngun.... 
You`re and addict now and destined to be skint forever...
Don`t polish the inlets too much by the way mate,water vapour will quickly condense into droplets on the polished surface and fook your airflow up....
Top,top project.......think this will be evolving forever..
You`re and addict now and destined to be skint forever...
Don`t polish the inlets too much by the way mate,water vapour will quickly condense into droplets on the polished surface and fook your airflow up....
Top,top project.......think this will be evolving forever..
02-06-2007, 03:07 PM
#179
PassionFord Post Whore!!
Thread Starter
Didn't give the inlets that much of a polish tbh, just cleaned them up a little, gonna pop over and do some more on it this evening..
I've got so much more to do to it... it's just time and money, I'm sure you know how this feels...
11-06-2007, 12:51 PM
#182
PassionFord Post Whore!!
Thread Starter
Update time. quite a long one this so bear with me!
2nd June / 9th June / 10th June 2007
Following on from the last post, we had fitted the TPS... Next up was cutting an ally pipe to length to join the fuel rail.. This had to be perfect, and the ends of the pipe needed lots of care. If the pipe splits the o ring inside the two halfs of fuel rail, we're gonna have petrol all over the place, which won't be good. So extra care is taken, and the cut edges filed down to make them nice and smooth.. There must not be ANY snags or sharp bits, or we're in the shit! lol.
First thing I needed to do was to mount the throttle bodies on the inlet manifold to see how much we need to cut.. a few caluclations later, and job done, pipe cut, and filed down ready to go in!
Bodies ready to be mounted on the manifold.
Pipe ready to be cut.
Bodies on manifold, the pipe goes between the middle two, just above on the fuel rail!
One pipe cut ready to have fuel shoved through it!!!
Done! Looks a bit wonky because the bodies are bolted to the manifold yet.
Next up was making a start on modded the standard loom for the injectors, so it works with the omex. We broke off all the plastic casing and cut off the ford connector on the end so we can conenct the omex connector. And that's it for now.. We'll come back to that in the next update no doubt.
The following day I was at ShawSpeed at 7.15am! Why? because we were off to Mallory Park to watch the 750MC kit car race... They had some great cars on, including a lovely throttle bodies ST170 Focus! and.... this kit car, running a ShawSpeed engine..
It was running a 1.6 Zetec-SE engine (same as mine) with cams, carbs, headwork etc etc, around 175bhp and 7500 limiter.
Bare in mind this car was running in the lowest class (1600) and running with 1800 Zetec's as well as other big engines (A class goes upto 3500cc engines!)... and guess where it came? 1st... in Both races.
Not bad for a fiesta engine, eh?
Bike engined Kit car race.
What a good day!
Fastfoward to Saturday the 9th, and I was bolting the throttle bodies onto the manifold... It was a very tight fit, but thankfully they went on... At least we know they'll be tight against the manifold!
Half way through bolting it on!
Bolted on
Next was fitting the fuel pressure reg, i'll explain more about this, when I learn properly what it does, lol.
The fuel pressure reg,
And where it shall sit!
The next job of the day was modding the water outlet on the side of the head to house a water temp sensor for the omex. This involved drilling a hole and tapping it for the sensor to screw in, and then tightneing it up so it doesn't let out any water. Once drilled and tapped we had to file the hole down to make sure it was smooth, and to ensure the sensor sits nice and flat, therefore holding all the water in.
Before, to the right of the cam cover, under the coilpack..
During!
Water everywhere, can you see the footprints all over the place? That's because I was angry because it was tricky to get on.. PMSL.
And after! done!
Next was the painful stuff.. sorting out this massive wiring loom! It wasn't as hard as I thought to be honest.. the wires that go to the standard ECU, were cut shorter as they won't need to travel far at all to reach the omex... This keeps everything tidy, and not loads of wiring hanging around.. and then we started taping this up to keep it nice and neat... There's still a bit to do on the wiring side of things, like fit all the sensors etc, but it shouldn't be too hard, hopefully.
So we're turning this...
A little neater and keeps things tidy.
Also over the weekend, I had the engine in at the moment rolling roaded, this produce 150bhp and 125lbs/ft torque.. a good basis for throttle bodies I should think
Pretty much most things done now, just need to swap the head, cams and shims, and wire in the sensors... Next update should be next week I should think..
2nd June / 9th June / 10th June 2007
Following on from the last post, we had fitted the TPS... Next up was cutting an ally pipe to length to join the fuel rail.. This had to be perfect, and the ends of the pipe needed lots of care. If the pipe splits the o ring inside the two halfs of fuel rail, we're gonna have petrol all over the place, which won't be good. So extra care is taken, and the cut edges filed down to make them nice and smooth.. There must not be ANY snags or sharp bits, or we're in the shit! lol.
First thing I needed to do was to mount the throttle bodies on the inlet manifold to see how much we need to cut.. a few caluclations later, and job done, pipe cut, and filed down ready to go in!
Bodies ready to be mounted on the manifold.
Pipe ready to be cut.
Bodies on manifold, the pipe goes between the middle two, just above on the fuel rail!
One pipe cut ready to have fuel shoved through it!!!
Done! Looks a bit wonky because the bodies are bolted to the manifold yet.
Next up was making a start on modded the standard loom for the injectors, so it works with the omex. We broke off all the plastic casing and cut off the ford connector on the end so we can conenct the omex connector. And that's it for now.. We'll come back to that in the next update no doubt.
The following day I was at ShawSpeed at 7.15am! Why? because we were off to Mallory Park to watch the 750MC kit car race...
They had some great cars on, including a lovely throttle bodies ST170 Focus! and.... this kit car, running a ShawSpeed engine..It was running a 1.6 Zetec-SE engine (same as mine) with cams, carbs, headwork etc etc, around 175bhp and 7500 limiter.
Bare in mind this car was running in the lowest class (1600) and running with 1800 Zetec's as well as other big engines (A class goes upto 3500cc engines!)... and guess where it came? 1st... in Both races.
Not bad for a fiesta engine, eh?
Bike engined Kit car race.
What a good day!
Fastfoward to Saturday the 9th, and I was bolting the throttle bodies onto the manifold... It was a very tight fit, but thankfully they went on... At least we know they'll be tight against the manifold!
Half way through bolting it on!
Bolted on
Next was fitting the fuel pressure reg, i'll explain more about this, when I learn properly what it does, lol.
The fuel pressure reg,
And where it shall sit!
The next job of the day was modding the water outlet on the side of the head to house a water temp sensor for the omex. This involved drilling a hole and tapping it for the sensor to screw in, and then tightneing it up so it doesn't let out any water. Once drilled and tapped we had to file the hole down to make sure it was smooth, and to ensure the sensor sits nice and flat, therefore holding all the water in.
Before, to the right of the cam cover, under the coilpack..
During!
Water everywhere, can you see the footprints all over the place? That's because I was angry because it was tricky to get on.. PMSL.
And after! done!
Next was the painful stuff.. sorting out this massive wiring loom! It wasn't as hard as I thought to be honest.. the wires that go to the standard ECU, were cut shorter as they won't need to travel far at all to reach the omex... This keeps everything tidy, and not loads of wiring hanging around.. and then we started taping this up to keep it nice and neat... There's still a bit to do on the wiring side of things, like fit all the sensors etc, but it shouldn't be too hard, hopefully.
So we're turning this...
A little neater and keeps things tidy.
Also over the weekend, I had the engine in at the moment rolling roaded, this produce 150bhp and 125lbs/ft torque.. a good basis for throttle bodies I should think
Pretty much most things done now, just need to swap the head, cams and shims, and wire in the sensors... Next update should be next week I should think..
12-07-2007, 04:33 PM
#187
PassionFord Post Whore!!
Thread Starter
Started again on it this week, once I get a bit more doen I'll do a write up again!
All we need now is a weekend to swap cams, heads, etc.
Starting the wiring next week, then its going for mapping at Powerformance in essex, by a fella called Steve of Race engine calibration services? (I think thats what it's called!)
12-07-2007, 07:40 PM
#190
Part of the Furniture
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Originally Posted by YoungDan
Started again on it this week, once I get a bit more doen I'll do a write up again!
All we need now is a weekend to swap cams, heads, etc.
Starting the wiring next week, then its going for mapping at Powerformance in essex, by a fella called Steve of Race engine calibration services? (I think thats what it's called!)
12-07-2007, 09:27 PM
#191
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Originally Posted by YoungDan
Started again on it this week, once I get a bit more doen I'll do a write up again!
All we need now is a weekend to swap cams, heads, etc.
Starting the wiring next week, then its going for mapping at Powerformance in essex, by a fella called Steve of Race engine calibration services? (I think thats what it's called!)
12-07-2007, 10:10 PM
#192
PassionFord Post Whore!!
Thread Starter
I had 150% brilliant customer service and mapping at MSD, they were fantastic. BUT I'm going where Jon as Shawspeed sends his cars, basically so he can have a map, but he assures me the mapping will be spot on
22-07-2007, 01:59 PM
#197
PassionFord Post Whore!!
Thread Starter
Sorry team! Having trouble sending pics fomr my phone to my computer! once I sort it I'll give a huge update
AGAR- I wish the car had as much attention to detail
AGAR- I wish the car had as much attention to detail
22-07-2007, 07:19 PM
#198
Borg Warner EFR Equipped!
Join Date: Apr 2005
Location: In the unit, building a 450bhp Time Attack Focus!
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Dan - i never thought i'd say this to you - but you've earnt my respect
Cracking stuff and well done for getting your hands dirty and learning about it
Cracking stuff and well done for getting your hands dirty and learning about it
22-07-2007, 07:30 PM
#199
PassionFord Post Whore!!
Thread Starter
Thanks Will 
Been a fucking HUGE learning curve, and I've enjoyed every minute of it, it's coming to the end of the project now, and I need a fix on something else
I blame The Diva for starting the ball rolling
I think next I'm probably either gonna...
A) fit a rollcage and forget about it
B) start tidying it up..
But TBH, I don't really wanna spend anymore money now, just wanna start enjoying it.
Should be all up and running by Thursday night.
Been a fucking HUGE learning curve, and I've enjoyed every minute of it, it's coming to the end of the project now, and I need a fix on something else
I blame The Diva for starting the ball rolling
I think next I'm probably either gonna...
A) fit a rollcage and forget about it
B) start tidying it up..
But TBH, I don't really wanna spend anymore money now, just wanna start enjoying it.
Should be all up and running by Thursday night.