Mk4 Rick

The link ive sent you will get the car up and running ive used it my self when i grafted a loom in to a mk2 fiesta

CR41G_86

update

engine is in !! what a squeeze!! but we did do it the hard way as we didnt removed the radiator or brake master cyclinder, basically we lifted the car with the engine crane wheeled the engine underneith with my engine jack and slowly lowered the car back down while shimmying the engine to miss the radiator and lower arms etc then we lifted the engine up on to the custom mount and then raised the gearbox to the front mount and bolted it up loosely then jacked the back of the gear box up to line it up with the rear mount, also refitted the gear linkage and a few other bits and pieces need to trim the slam panel abit more as the exhaust heat shield is in contact with it and im removing the egr valve pipes off the manifold as they are making contact with the fan housing and make the engine bay look so crammed its unreal !!

but its in lol

picture of the new fan belt set up



few pictures of the engine before fitting





and a few of it fitted into the car









in the metal the engine looks truly massive in the little ka but at the same time looks awsome!!

over the next few weeks ill be tackling the electrics and plumbing and the few other little jobs i need to do to get it running i will post as much info as i can for you all

just bloody chuffed its in

CR41G_86

sorry bout the last pictures i had the shakes due to having suger rush off a can of relentless due to not eating anything all day doh!!

Dan j

which engine mount did you use ? Any pics, ps could you be detailed in regards to the wiring loom for this as I fancy doing it to mine

CR41G_86

3 mounts hold the lump into the car and 2 of which are on the gearbox ,so because your using a ka gearbox you only need 1 drivers side mount which is custom made , the actual mount is an escort rs turbo rubber mount and cup the cup has to be modified to fit the engine and the the lot bolts up to a custom plate on the first page theres pictures of what it looks like and what was to be modified etc

as for wiring unless you have the exact same car made in the same year and use the exact same engine and ecu and loom it would be dificult to replicate but ill post the way i had to do things with pictures when it comes to that time

plumbing in the cooling system seems very straight forward using some ka hoses , some escort hoses and a mk2/3 mondeo bottom hose.

ill do my best to keep this update as im sure in the future this thread would be very helpfull for some one

CR41G_86

update

ive cut out the ka engine loom being carefull not to cut any earths or lives also had to unravel the loom to remove the side repeater , headlight , front indicator ,horn ,reverse light and radiator fan wiring to make sure these was not cut, bloody took ages unraveling the stupid electrical tape.

ive also refitted all the engine to chassis earths and fitted the rs1800 loom to the car , ive given the rs1800 ecu a temp constant live and earth but still need to figure out which is the ignition switch live on the rs1800 plug

but anyway had it turning over with the key tonight so not to bad

question
does the fuel pump run off the rs1800 loom or the ka's ?? because if its the rs loom i need to figure out which they are on both looms and get them connected up.

Hobomassiv

You could just run the fuel pump from a seperate ignition feed off the column and a relay?

CR41G_86

im going to have another crack later ,ive got my hands on a bit of info that might add up to my loom so if it does ill post up my findings

CR41G_86

right had a bit of a break through

had it running . . . for 5 seconds a time at a guess the fuel pump is priming but not running so the engine runs then cuts out when runs out of fuel , when the engine was about to die i sprayed in some easy start and it kept it running until it burnt all that then died

at a guess when cutting the ka engine loom out ive cut a live or earth for the fuel pump doh!!

really need an ecu pin out for the ka 'area' ecu if any one can help because i dont have a clue to be honest now

AaronsKa

Do you not have a Haynes manual to hand? Be easy enough to wire in a fuel pump feed.

NoRubNoDub

What about just hard wiring it with a switch?

CR41G_86

all sorted and engine is running!!

in the end i spliced into the ignition switch live and connected it to the inertia switch but this ment as soon as the ignition was turned on the fuel pump was running so ive added a rocker switch so if anythin itll be a good antitheft measure, if sum twat tried to nick it they would never get it goin unless they found the switch lol

im also putting the cooling fan on a rocker switch and adding a temperature gauge aswell as a rev counter as the signal wires are readily available off the rs ecu

any way heres a short video of it running ( no down pipes or cooling system )

http://www.youtube.com/watch?v=PQJp9...hX5bUkXRyJhcbo=

il post up the wiring info in the next few days for any one thats interested

Dan j

Well done mate, post the wiring info up as I'm interested also which clutch did you use

CR41G_86

cheers bud will do

and its on an rs1800 clutch

PhilCook

iTrader: (1)

Looking good

NoRubNoDub

Cheers, loving the flames out of the exhaust

CR41G_86

lol i didnt even realise the flames kicking out the manifold until i watched the video my couson filmed it while i cranked it and gave it a few blips on the throttle

it was so nice to get it to run spent all day rewiring both looms and retaping everything back together ,still got a few things to finish off namely the oil warning light which i think just needs to go to earth and i need to run the temperature signal wire and rev signal wire but need to get the gauges first !!
so yea not much left to do with wiring now

CR41G_86

little bit of wiring info for those that are interested

on the rs1800 engine bay loom theres 3 plugs of which 2 of them goes to the engine sensors .

the 3rd plug is as follows

pin 1 - brown = earth to body ( i ran a new earth for this)
pin 2 - green = rev counter signal (does not work if your using an after market rev counter)
pin 3 - brown = fuel pump earth ( i just earthed this as the ka ecu is running the pump)
pin 4 - black = 4 amp ignition live (i ran a new wire from ignition with a 4amp fuse )
pin 5 - black/red = idle speed control valve earth (i ran a new earth for this)
pin 6 - red = constant live from battery or fuse box
pin 7- brown/green = oil warning light
pin 8 - black/green = idle speed control valve live ( i ran a new ignition live for this)
pin 9 - brown/white = temperature gauge signal (decided not to use it and installed and after market temp sender)
pin 10 - blank = not used
pin 11 - blank = not used
pin 12 - blank = not used

i accidentally cut about 7 wires when removing the ka's engine loom in the end i found what the wires were for and connected them back up ,however i traced the wire from the oil light on the ka loom and the oil light switch on the rs1800 loom and was able to solder them together to get the oil warning light working on the dash from the zetec engine .

also if i had my chance again i wouldnt cut the ka's engine loom out id just hide it as its cost me around 8 hours of time rewiring things because of the fuck up .

anyway hope this helps and im moving on to water system shortly so will post up info of this as and when i start it .

only real update is that ive reloomed everything and put all the plastic loom covers back on and tidied up the engine bay

still need to get the securing clip for the gearbox clutch fluid pipe and bleed the clutch ,need to shorten the engine fuel pipes as the ka fuel pipe clips dont reach the locking bit , sort the cooling system refit battery box and battery and then make up an air intake pipe and figure out were to mount the air filter.

ill get some pictures of progress in the next few days

Dan j

Top effort matey

mk3cosproject

love this thread after giving me inspiration looking for a donar mondeo now lol

CR41G_86

cheers guys

its getting there slowly i dont have much time to go in the garage and play so progress wil be slow and steady

its great fun working on it , but at the same time ive had head aches and sleepless nights because of it lol but the best bit is getting through all the problems and getting it running ,the first time it started and run i just felt all the preasure on me disapear and now im properly enjoying it.

i bought the car for 200 quid with tax and mot but a nakered engine but with the only intention of doin this conversion , i dont no if i could have done this to her if she was my pride and joy though

Dan j

Haha I'm never happy Untill I have a car in bits then I know nothing is hiding that could cause trouble later on.
I will be fitting a 115bhp escort gti zetec engine so ill he using the look from that.

1980blakey

iTrader: (1)

I just finished converting my ka from zvh turbo to zetec turbo but i didnt have to cut the slam panel as much as you. How long until you will be finished?

CR41G_86

had to cut the slam for the cam cover to fit properly and the oil dipstick, im still going to cut a bit more just to make it look cosmetically better as im not happy with the shape of it at the minute.

i dont have a time limit , was hoping to have it fully finished and road legal for ford fair in august but probably wont see the road until next year now lots of stupid little bits to do and going to have it resprayed ,new brake set up , suspension changes , new wheels and tyres , exhaust system etc the list goes on , id rather take my time and get it ready for next year rather than rush it for this year plus as said previous time is very short at the minute

CR41G_86

small update

got my hands on a mondeo bottom rad hose and a new horn and collecting a new passenger side driveshaft in the week , just need to get a clutch fluid pipe securing clip and it should be drivable when i get the cooling system sorted

mk3cosproject

care to list what the project needed?? would be much appreciated by alot of people, lots wondering in the clubs what they need including me. small bits too lol
as said epic build hope you throw up a vid of it running

CR41G_86

to just remove the ka lump you need a 13mm spanner , 13mm socket and rachet ,and a torx 55 bit which you can connect to a rachet .

pliers to remove all the water pipe clips
small electrical screw driver to remove the clutch fluid clip from gearbox
3 bolts holding the gear selector rods to the box and then just various wiring plugs to unplug.

engine crane to lower engine down then lift the car up and pull engine out from underneith , u also need to do this to fit the zetec engine.

to fit zetec engine you dont need a great deal

you need a custom mount plate for drivers side
an escort rs turbo rubber mount and backing cup (which needs moddifying to fit )
the other 2 engine mounts are on the ka gearbox

you need to cut the slam panel to give room for the exhaust cam and plastic cam cover when you fit it.

CR41G_86

small update

rev counter and water temp gauge now purchased

havnt really had chance to get in the garage and do some work on her but when i do ill get some more details and photo's posted up .

CR41G_86

another small up date

rev counter and water temperature gauge have landed along with a double dial pillar pod , how ever the pillar pod is way to big for my a pillar plastic so currently having a rethink as to were to put them .

other than that wiring is basically now complete just need to hide the rs1800 ecu and put the cooling fan on a switch

drive shafts have been wire brushed and repainted , just need refitting

still need to get a clutch fluid pipe securing clip and bleed the clutch!

also started gathering radiator hoses from scrap yards ,basically by the end ofthe month i want it running and driving then i can crack on with body work ,get some wheels and upgrade brakes etc

i should be doing some work on it the weekend so ill update with pictures

NoRubNoDub

Could you not put the two gauges in the center two air vents?

Dan_RS500

Nice one, love seeing a Ka getting a bigger engine! Some times wish I'd just done this with mine instead of going all mad with a grinder. Keep the updates coming!

CR41G_86

thought about the 2 central air vents but you need 82mm gauges and ive got 52 mm so no good , may just buy a custom made pillar pod specifically for the ka .

dan_rs500 - cheers dude

CR41G_86

update

it now drives !! (video to follow)

got the clutch sorted and bled up today
fitted the driveshafts

also been down the scrappers to get some more rad hoses and other bits and pieces

hoping to have it practically sorted by the end ofthe month which will then leave , brake upgrade , new wheels and tyres and respray

im also playing with the idea of stripping it for weight saving purposes only leaving drivers and passengers seats and seat belts door cards and dash and then fiting a front and rear strut brace. any thoughts?? ive read it could shed around 50kg of weight

NoRubNoDub

Could you not put a blanking plate in them?

CR41G_86

thought about that aswell but i dont no if i can be arsed making summet to blank it off and i dont no if any companys make anything to do the job.

any way

heres the video of its first ever drive out the garage

http://www.youtube.com/watch?v=BP0XI8N6Klc

Dan_RS500

You can blank the vents easy enough using some aluminium or carbon fibre sheet cut roughly into circles and stuck in from the back of the holes with tiger seal or similar. Be sure to cut the holes or what ever in the sheet before you stick them in.

CR41G_86

i think im going to keep the air vents as vents rather than blank them off , might just get some dash mounting gauge pods rather than a pillar pod , just wished there was sumwere on the dash to drill 52mm holes that were in eye line .

CR41G_86

few pics

descent pic of the engine bay



and just a random picture of the dash

CR41G_86

another small update

rewired the rad fan so now its on a switch
moved the edis 4 unit so now its behind the brake servo which now leaves room for the cooling system and expansion tank.
wired up another switch to power up my gauges
and ive had a change of thought and after looking at it , it makes sense to remove the middle airvents blank them off and fit my gauges there so should get all the wiring finished over weekend .
need another trip to the scrap yard to get some more rad pipes and other bits but yea its coming on now

CR41G_86

ive removed the 2 central air vents , surrounds and plastic pipe work to make space for my gauges and ive blanked off the pipe comming out the heater box to stop heat build up behind the gauges once there installed its all wired up and works (other than a little issue with the rev counter that ive posted in the car discussion forum)

just need to get my hands on a bit of perspex to cut to shape and bond in to house the gauges and to fill the blank space around them will post a picture once its done.

electrics now very close to being finished just niggley little bits that just seem to take for ever