rscossie86

looks very nice...

hlev

Brilliant work's going on here.

XR2

Oil cooler adapter needed a good cleaning






New and old oil temperature sensor




Finished the bracket for the idle control valve






RS1600i inlet with the painted brackets for the fuel rail




oil pressure sensor fitted

XR2

Had some problems with the internet the last few days...


I put in the oil cooler






Put in the MAP




My "old" coolant hoses... bought them all new in 2006




FINISHED THE ENGINE!!!!

Mr.T

I just read your topic again but do the EFI injectors fit straight in the MFI injector holes?

Brian

iTrader: (2)

Very nice mate


Brian

c.fogarty

Would like to know also.........

Is that the original MFI plate (drilled for EFI injectors) between manifold & head???

Cheers

fezzajsy

iTrader: (9)

looks very good

XR2

Sorry, I just saw that someone answered... got no notification (probably because of the new forum).

We used the standard MFI plate. We used it because I wanted to keep the RSi inlet and there's a modded RSi head on this engine.

Holes for the injectors are at the same place like they were for the MFI ones, we just made the holes bigger so that the EFI injectors (XR2i CVH) fit.

Mr.T

ok nice. About the notification. I have the some prob.

chrisyturbo1

i love the xr2 might see if i cant get me a mk1 and do what you have but maby a turbo 1
but its hard to find a nice mk1 shell as the english weather is so shit lol

XR2

And there are not many Ford fans in Germany, so it's much harder to find a MK1 or MK2.

There are not more than 10 XR2 MK1 or MK2 for sale the whole year...

XR2

UPDATE!!!!!!!!!!

Yesterday we pulled the car to my father's house where I can use his garage again.

Today I began to localize the problems of the injection.

Got a new idle control valve. It's a Ford remote one, like it was used in the first 1.6 EFI in XR3i and XR2i until ~91.






all the parts... really dirty inside with dust and oil, so I gave them a good clean with brake cleaner





after cleaning I primed them




and again Rallye Silver and clear lacquer




before and after:




the VW VR6 icv I tried before, wasn't working well




bought a new bonnet catch, hoping the clear laquer will do well so it will look good for a long time

Mr.T

Did you got any benefits from using the stand alone system on your 2i engine?

XR2

I don't use a 2i engine. It was a modded CVH engine with RS1600i parts except from the ignition. Standard ECU is always a problem with tuning. Idle was horrible with the sports camshaft, and i had fuelling and power problems at full throttle. So I decided to buy a full mappable injection and ignition.

XR2

Found some pics we made last year.

Tested the spray pattern of the injectors and the amount of fuel

Mr.T

Well apart from the head and maybe the compression there isnt that much of a diff. But no real changes in HP figure?

XR2

RS1600i had a reworked head, higher compression, lightened inlet valves, 272° camshaft, mechanical tappets, bigger manifold, different exhaust, modified fuel distributor, big throttle body, modified inlet. RS1600i had 115 hp standard, XR2i and XR3i had 105 or less hp. No comments on my power fig

Mr.T

thanks for the spec. Why no HP figures? Like to know it now. And yes i know the 3i has 105HP I hate it to but who cares. Getting loads more next year But not on a 3i engine thats for sure

XR2

My engine is far beyond RSi spec. Not sure about the bhp/PS. Has not been on the rollers yet

Mr.T

Get it on the rollers then. Its good to know what you have.

XR2

It's still very cold outside and not much fun working on the car



Made a new bracket for the icv today

hai07222

Coming along nicely, good work

XR2

Spent some time on the bootpanels




And the last Samco hoses arrived. Two big ones for the icv and rocker cover -> air filter box, and the two small vacuum hoses for the fuel pressure regulator and the map




I'm gonna drop all heavy HIFI-equipment including the amp so I just use four small speakers which will be connected to the headunit via the ISO-plug




13 cm speakers are a little bit too big, but after some work with the grinder they will fit fine

XR2

It's getting time to get the engine running, so we sorted the problems out:

1. Lambacontroller (Innovate LC-1 with VW/Audi Bosch LSU 4.2 wideband lambda unit) always lost calibration and programming

-> updated the firmware, used a relais to power it and used a single mass connection to the battery just for the controller, it's working now as it should

2. Engine often refused to start, and then it ran only on three cylinders

-> changed an odd looking spark plug

3. Engine still didn't want to start

-> checked spark... too weak, on cyl 2-4 even to weak to give a signal to the flashin pistol we use to adjust the offset of the OT sender: RSI twin coils fucked up

4. not working RSi twin coils

-> I fucking love those things. But there's no use of parts that don't work. So I used a twin coil out of an 1.1 MK5 Escort with CFI and EDIS. Car started at once, but still just running on 3 cylinders

5. another (genuine Ford Motorcraft AGP901C Escort Turbo) spark plug not working

-> bought a new one

6. ignition coil(s)

-> 1.1 is not the solution... HT leads are too long, wrong bracket for the coil. So I drove 100 km to a friend of mine and got the twin coil, the bracket and the HT leads out of his winter-XR2i 8V

7. HT leads

-> The XR2i ones are too long, these should be clipped into the black plastic inlet of the EFI. A friend of mine posted me a set off an 1.4i, should fit better

8. colour

-> there are no blue HT leads for the 1.4i / PTE available. I'll get me some later spec twin coils (Focus etc.) and make some custom-made leads


Wondering if the car will run on saturday. We'll have to make some non-load tests for the ECU...

In the meantime I did some minor work:


primed the twin coils bracket:




fitted the blanking plug for the camshaft hole




painted the bracket... Rally Silver like all the other parts






fitted the XR2i coils and the HT leads






cut a hole in the cambelt cover so that you can see the blue vernier pulley and painted it in satin black

fezzajsy

iTrader: (9)

looking very good

XR2

It was time to get rid of my daily driver after I owned the car for 8 years now. A 1.4 16V Opel Corsa B. I still like the car but ten years is too much for an Opel used daily.







To replace the Corsa I bought a Fiesta ST. The colour royal grey isn't available in the UK for the ST and also not very common here. I'll get rid of the stripes the next days, lower it about 30 mm and buy some aftermarket wheels.





The first thing I replaced was the plastic gear knob with this shiny Focus RS one and the gaitor is out of a Fusion.



I also spent some time on the XR2. The lambda controller caused many problems, so I bought another one. And voilá, no problems with lost sensor calibration and lost analog output programming.

XR2

Pulled off the stripes and gave the ST a good clean. Just needs lowering springs and new wheels now!













But now it's time to spend some time on the XR2!!!

AGAR-COSWORTH

Hows the XR2 coming along now then?

XR2

Stored away for the winter. Last year I didn't feel like finishing it. From March or April on I'll give it the finishing work. New ignition coil and HT leads, some chrome parts for the engine bay, put in back my old VDO instruments for oil temperature, pressur and volts, and fit another center console. Maybe I'll fit my König seats also. I'll keep you updated...

AGAR-COSWORTH

Glad to hear its still around - looking forward to seeing it finished then.

DaveCrack

iTrader: (1)

Nice work here! Hope to see the car finished at a meet this years summer!

XR2

That's the plan

XR2

I lowered the ST using 30 mm Eibach springs.

This is how it looked after:

XR2

As mentioned above, I didn't like the standard wheels. So after a few weeks of waiting, these turned up on ebay:

7x16" RS7 diamond cut.



Painted in classical Ford diamond white. I've got made a set of classical RS-stickers (like they were on the caps of the RS 4-spoke) in black and white. Will be added soon.

Freed the car of all the stickers and stripes, this is the only thing left:



A fair tribute to one of the most inspiring rallye drivers in the world...

XR2

Last summer I had the chance to drive this thing a few hours:





I've got a new dream car now...

Think of the weight of a low-spek MK1 fiesta with about 3x the hp of the first XR2. A 2.0 direct injected turbo engine with nearly no turbo lag and the suspension of a formula race car.

It was a fine afternoon and so much fun to drive!

XR2

Ordered some new parts:











BMW 735i injectors


Bailey header tank in position. I'm very disappointed about this thing. Don't line up with the mounting holes for the standard item. Had to puzzle around how to mount it best.
And the cap was a total waste of money. I'll probably loose it on the first bump!

XR2

Didn't have much time last year, so the XR2 stayed in his garage most days. Had some trouble in my job and was on a degree in business administration, so evenings and weekends were also filled up with lessons and learning.

But now and then I found some time.

Started to make the front door cards. I'm not happy with the first example, the second one is much better. Will get dark grey or black suede or alcantara, a small handle and maybe the pockets of the GFJ. These door cards include the upper section like it was in XR2s and Ghias





This was left from my military service 12 years ago. Absolute no help when the sun shines, but it worked fine to get the door board easy off the wooden panel...


Well.. was my first try ever, second one is much better! I'll make this one once again...




And I've already got an idea for the rear ones. I've got bad looking spare ones lying around, I'll straighten them by changing the middle section so suede or alcantara can be put on easier.

XR2

The cable between alternator and starter caused some trouble. Well, after 25 years there are some parts which are out of order. Quite what you have to expect when you own a car like this and want to have everything as good as new.

XR2

Did some detailing work on the wiring loom, here you see one of the injectors. Used black shrink-on tube. Might make them new after I discovered they sell them also in blue