Pauls Stunning Zetec Turbo Powered ERST
11-09-2009, 09:11 AM
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Pauls Stunning Zetec Turbo Powered ERST
You may recognise the car from FastFord about a year ago...
NOTE: This pic is after we connected up the IAT and reran the some of the wiring (It was all hanging over the inlet plenum, v messy!)
Anyway the story so far..
Paul brought his car to us after he had finished building the rather impressive Zetec Turbo that we have here, (Fully forged bottom end, cams, head work, Area 6 manifold, Big 'ole turbo the works) for us to fit and map our V3 ECU.
The idea was to create a running in map, that would allow Paul to clock up some miles on the fresh build before we took it any further..
The reult was 180bhp at only 4psi of boost, with SHED LOADS of torque (cant actually recall the figure as it was on our old dyno).
He put a fe whundred miles on it, and then needed the final mapping doing. The probleem was that Paul lives about 160 miles from us, and in the end he thought it easier to go to a local tuner in Kent. (I wont mention any names)
Well, after six weeks, and this so called 'tuner' calling m,e asking why the ECU had stopped injecting on 2 injectors, with me then asking 'Have you changed the injectors to low-impedance' and have you also set the ECU to work with Low-Z injectors?' I was met with silence on the phone, and the question: "How do I know if they are Low impedance?"
It was at this point (some six weeks after Paul had taken the car there) that he decided enough was enough and trailered the car back to us
We had an interesting couple of hours looking over the car...
Apparently, you don't need an Inlet Air Temp sensor anymore, or so this other tuner thought as this one was left unplugeed for some reason, and whilst they were at it they decided to wire the TPS sensor in the wrong way round.... using spade connectors of course (instead of soldering and heatshrinking as per the rest of our wiring loom!
Also, they found it best to not connect the manifold pressure sensor up, which I find can sometimes effect the running of a vehicle which has constantly varioable manifold pressure...
Onto the good bit. We sorted the ECU, fixed the wiring, and have now got the car idling.
Pauls hoping for over 300bhp and I am to supply!
Updates to follow....
P.S Beware of garages that go out and buy a rolling road, when they have been doing servicing and fitting exhausts for 20 years. They may be great mechanics, but that doesent make them an expert on vehicle electrics, mapping, or the principles and maths that goes into making an engine management system work. I am sure loads of people have found the same out there! The Dyno arrived here before the ramps, and I employ a mechanic as theres not a chance in hell I would wanna get involved with rebuilding a head! (I have never done it, nor will I probably ever try) Theres also an auto electrician working here who can solder, and pulls faces when people netion scotch locks and chocolate blocks! Arghh
Sorry, just hate fixing other peoples bodges, and feeling sorry for customers who have paid someone to do a job which they are simply not qualified for. If you have a dyno, but you don't know what MBT is... stick to power runs.... rant over!
NOTE: This pic is after we connected up the IAT and reran the some of the wiring (It was all hanging over the inlet plenum, v messy!)
Anyway the story so far..
Paul brought his car to us after he had finished building the rather impressive Zetec Turbo that we have here, (Fully forged bottom end, cams, head work, Area 6 manifold, Big 'ole turbo the works) for us to fit and map our V3 ECU.
The idea was to create a running in map, that would allow Paul to clock up some miles on the fresh build before we took it any further..
The reult was 180bhp at only 4psi of boost, with SHED LOADS of torque (cant actually recall the figure as it was on our old dyno).
He put a fe whundred miles on it, and then needed the final mapping doing. The probleem was that Paul lives about 160 miles from us, and in the end he thought it easier to go to a local tuner in Kent. (I wont mention any names)
Well, after six weeks, and this so called 'tuner' calling m,e asking why the ECU had stopped injecting on 2 injectors, with me then asking 'Have you changed the injectors to low-impedance' and have you also set the ECU to work with Low-Z injectors?' I was met with silence on the phone, and the question: "How do I know if they are Low impedance?"
It was at this point (some six weeks after Paul had taken the car there) that he decided enough was enough and trailered the car back to us
We had an interesting couple of hours looking over the car...
Apparently, you don't need an Inlet Air Temp sensor anymore, or so this other tuner thought as this one was left unplugeed for some reason, and whilst they were at it they decided to wire the TPS sensor in the wrong way round.... using spade connectors of course (instead of soldering and heatshrinking as per the rest of our wiring loom!
Also, they found it best to not connect the manifold pressure sensor up, which I find can sometimes effect the running of a vehicle which has constantly varioable manifold pressure...
Onto the good bit. We sorted the ECU, fixed the wiring, and have now got the car idling.
Pauls hoping for over 300bhp and I am to supply!
Updates to follow....
P.S Beware of garages that go out and buy a rolling road, when they have been doing servicing and fitting exhausts for 20 years. They may be great mechanics, but that doesent make them an expert on vehicle electrics, mapping, or the principles and maths that goes into making an engine management system work. I am sure loads of people have found the same out there! The Dyno arrived here before the ramps, and I employ a mechanic as theres not a chance in hell I would wanna get involved with rebuilding a head! (I have never done it, nor will I probably ever try) Theres also an auto electrician working here who can solder, and pulls faces when people netion scotch locks and chocolate blocks! Arghh
Sorry, just hate fixing other peoples bodges, and feeling sorry for customers who have paid someone to do a job which they are simply not qualified for. If you have a dyno, but you don't know what MBT is... stick to power runs.... rant over!
Last edited by M-Tech Automotive; 11-09-2009 at 09:16 AM.
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12-09-2009, 07:31 AM
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12-09-2009, 04:22 PM
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At least someone knows
Hence why dyno-tuning will usually give the BEST torque all accros the map, as you can accurately measure the torque generated at that particular point, and then there is no need to advance any further (ie find the point, back off timing until it drops, then knock it up a touch etc, or advance advance until power drops away, then back it off a few degrees etc. You should technically not need det-cans when mapping with a dyno, but you would certainly need them with road mapping.
Hence why dyno-tuning will usually give the BEST torque all accros the map, as you can accurately measure the torque generated at that particular point, and then there is no need to advance any further (ie find the point, back off timing until it drops, then knock it up a touch etc, or advance advance until power drops away, then back it off a few degrees etc. You should technically not need det-cans when mapping with a dyno, but you would certainly need them with road mapping.
12-09-2009, 07:04 PM
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Yeh its a big pole turbo. Will check with paul the exact spec as theres not much in the way of visible markings.
Will get some more pics up when back at work Monday.
Will get some more pics up when back at work Monday.
15-09-2009, 03:46 PM
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yes your spot on mate, its a GT30. If anybody has a zetec turbo and wants it tuned/set up or maybe even aftermarket management fitted ! Matt and his guys at M-TECH Automotive are the people to do it ! even if you've got a N/A Zetec on throttlebodies Matt is the man. ive had some bad experiences with other tuners as matt explained and M-TECH Automotive have never let me down, always pleased with the service that they provide. TOP TUNER !! i highly recomend them.
if anyone has any technical queries about the build feel free to ask.
regards paul
15-09-2009, 07:39 PM
#21
yes your spot on mate, its a GT30. If anybody has a zetec turbo and wants it tuned/set up or maybe even aftermarket management fitted ! Matt and his guys at M-TECH Automotive are the people to do it ! even if you've got a N/A Zetec on throttlebodies Matt is the man. ive had some bad experiences with other tuners as matt explained and M-TECH Automotive have never let me down, always pleased with the service that they provide. TOP TUNER !! i highly recomend them.
if anyone has any technical queries about the build feel free to ask.
regards paul
if anyone has any technical queries about the build feel free to ask.
regards paul
you know you want more lol the turbos there for it
15-09-2009, 08:24 PM
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Its going to be interesting. It does lag a little though, but it made 180+bhp at 4psi thus far. A smaller turbo could be something worth looking at, will have to see how it goes once we get stuck into the mapping.
Matt
Matt
18-09-2009, 03:47 PM
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22-09-2009, 10:28 AM
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I wont disclose the company that did the bad work, and I ojly reported what we saw on the car, if Paul wants to say I'm sure he will lol
Will get some pics of it on the Dyno as well, had to sort another little issue with the starter but that all working fine now.
Matt
Will get some pics of it on the Dyno as well, had to sort another little issue with the starter but that all working fine now.
Matt
23-09-2009, 04:50 PM
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good engine and gearbox choice
28-09-2009, 11:18 AM
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Well well...
We thought we solved the starting issue (put it down to a sticky starter, have it a tap and away she went) but this turned out to be a lucky movement of wiring..
We went to drive the car back into the dyno, whereupon we noticed a trail of oil...
After speaking to paul, and carrying out an inspection, turns out the following has happened..
Unbeknown to us, when thw aforementioned place installed the new manifold, they cut the cable ties that secured the turbo oil feed hose. This braided hose now rests near the starter terminals! It has a very intermittant contact, but the contact it has had has melted the hose (our starter issues), and therefore allowed the oil to flow nicely out of it. Paul is now sending down another hose so we can crack on with the mapping.
Arghh, it ran so well when it left last time!!
Matt
We thought we solved the starting issue (put it down to a sticky starter, have it a tap and away she went) but this turned out to be a lucky movement of wiring..
We went to drive the car back into the dyno, whereupon we noticed a trail of oil...
After speaking to paul, and carrying out an inspection, turns out the following has happened..
Unbeknown to us, when thw aforementioned place installed the new manifold, they cut the cable ties that secured the turbo oil feed hose. This braided hose now rests near the starter terminals! It has a very intermittant contact, but the contact it has had has melted the hose (our starter issues), and therefore allowed the oil to flow nicely out of it. Paul is now sending down another hose so we can crack on with the mapping.
Arghh, it ran so well when it left last time!!
Matt
Last edited by M-Tech Automotive; 28-09-2009 at 11:19 AM.
28-09-2009, 11:29 AM
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top project fellas, may i ask who supplied your 5 speed shafts as ill be needing some shortly and if you dont mind the cost for them? pm if you wish, cheers
28-09-2009, 03:30 PM
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Well well...
We thought we solved the starting issue (put it down to a sticky starter, have it a tap and away she went) but this turned out to be a lucky movement of wiring..
We went to drive the car back into the dyno, whereupon we noticed a trail of oil...
After speaking to paul, and carrying out an inspection, turns out the following has happened..
Unbeknown to us, when thw aforementioned place installed the new manifold, they cut the cable ties that secured the turbo oil feed hose. This braided hose now rests near the starter terminals! It has a very intermittant contact, but the contact it has had has melted the hose (our starter issues), and therefore allowed the oil to flow nicely out of it. Paul is now sending down another hose so we can crack on with the mapping.
Arghh, it ran so well when it left last time!!
Matt
We thought we solved the starting issue (put it down to a sticky starter, have it a tap and away she went) but this turned out to be a lucky movement of wiring..
We went to drive the car back into the dyno, whereupon we noticed a trail of oil...
After speaking to paul, and carrying out an inspection, turns out the following has happened..
Unbeknown to us, when thw aforementioned place installed the new manifold, they cut the cable ties that secured the turbo oil feed hose. This braided hose now rests near the starter terminals! It has a very intermittant contact, but the contact it has had has melted the hose (our starter issues), and therefore allowed the oil to flow nicely out of it. Paul is now sending down another hose so we can crack on with the mapping.
Arghh, it ran so well when it left last time!!
Matt
good luck tho keep the updates coming
29-09-2009, 06:14 PM
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well impressed with them !
29-09-2009, 06:18 PM
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