1986 Ford Fiesta XR2 1.7 VVT Turbo

[jhot80]

Yer have a oil cooler fitted. Im gonna plumb back in the water cooling for the turbo but it was the map that melted the turbine.


Head has come back from the machine shop.

Had a few hours after work so got it together and...

One engine ready to go in bar a few bolt on bits.


I did end up getting stung for import duty bugger. still worked out quite cheap just slowing up delivery.
I shall make a start on getting the engine in the car next week. I am off to scotland this weekend for Downhill mtb race.


Im waiting on a new driveshaft to turn up from a puma. Hopefully gonna be able to change the outboard CV and get away without changing much else to go equal length shafts. so we will see how that pans out hopefully well that way tune out a bit of torque steer. My plan once the engine is mapped is to refine the suspension and and chassis to minimise the torque steer as much as possible before fitting a LSD.

 

[jhot80]

New Turbo has arrived. Looks pretty good haven't compared it to the old one yet but it does look a bit bigger looking forward to getting it back together just waiting for my engine crane to come back from a friend then full steam ahead.

​

 

[jhot80]

The engine is all in the fiesta now and I'm just waiting on a few things to get it back on the road.


Top of the list was this little thing.

I changed the CSC when I had the engine and box out as the old one was well quite old and crappy but what i didnt realise is that around 2008 ford changed the design of the quick connect and the line that I had piece together no longer fitted and take the engine out was way too much work to put the old CSC back in. So I got the drawing out and had this made to adapt it to An-3 fitting. Which is much better as i already have the hose just need to buy a couple of fittings.


Next is the driveshaft. I want to get rid of the long driveshaft as i think its one of the major sources of torque steer in the fiesta. Lucky the pumas a fitted with equal length driveshafts and the link shaft and bracket are easy to get hold of and the spline count on the puma IC shaft and the fiesta shafts is the same. I got hold of the Link shaft and measured that up. lucky the guy that sits next to me at work did use to work in the halfshafts department and was able to do the math for me and work out that i needed a a 325mm shaft clip to clip and puma shaft is 358mm clip to clip which would require sleeving to shorten which makes me nervous and would create a massive stiffness imbalance left to right and possible make the torque steer worse not achieve anything.


So i started looking thought the back catalog for ford to find the smallest shaft i could Ka come out at 342mm still too long then i took a look at the standard xr2 short shafts 335mm. They guy that does the machining for me is confident he can get 9mm out of the shafts installed length by cutting new clips seats and extending the splines slightly and taking a bit off the end. not ideal but better then sleeving the shaft and should give me pretty good balance and cure a good chuck of the torque steer.


My new shaft turned up the other day i just need to clean it up and then get it over to the machine shop.


I think the other major contributor to torque steer is the tie bar suspension system. I have got poly bushed tie bar bushes but i think that they are give and not to mention create a lot of hysteresis in system because they resist movement of the system unless the tie bar bush is in it natural position. Only solution for this is the rose jointed kustom karl type suspension arms.

 

[jhot80]

Fitted up the Luk quick Connect to An-3 connector. Fits perfectly was a bit unsure on what thread the an-3 was supposed to have on it but got it spot on.

I also played a bit of a gamble and bought the kustom karl type suspension kit.

its quite good quality. Im fairly happy with it. will see how well it goes onto the car once the driveshaft has been machined. Guy chanced it at just trying a normal bit of tool steel and there was more material coming off the tool than the driveshaft lol. Wasnt slightly expected but would have been nice for it to be simple. Gonna grind off the surface of it and give it another go but hes away this weekend so will have to wait.


Starting to get withdrawal symptoms from not having driving anything remotely exciting for a few months now. So need to crack on and get this shaft sorted as its the main block to me putting back on the road as i cant be bothered to do the rest when it wont move.

 

[GiT]

Could that block of not been rescued with a slight bore out?

 

[jhot80]

Na the 1.7s are nakisil lined. They are lightly servicalble but over boring isnt possible. Ive looked into having the linjng recoated which is possible for motorbike engines but nowhere ive found does it for auto engines.

 

[Ph1 Tom]

Keep at it, it'll be worth the effort!

 

[NorthloopCup]

Na the 1.7s are nakisil lined. They are lightly servicalble but over boring isnt possible. Ive looked into having the linjng recoated which is possible for motorbike engines but nowhere ive found does it for auto engines.

There is places in the uk mate that recoat nikasil liners on car blocks. Expensive though and you've got to know where to go.

 

[Ph1 Tom]

Are steel liners possible?

 

[jhot80]

Not without reducing the bore and ending up heavily under square. At them moment the most cost effective way it just a good condition block.

 

[jhot80]

There is places in the uk mate that recoat nikasil liners on car blocks. Expensive though and you've got to know where to go.

Do you lnow these places?

 

[NorthloopCup]

Do you lnow these places?

Try Capricorn Automotive mate. They're in Andover. Nikasil is the name that's owned by mahle, the actual process is nickel ceramic coating on the liners. It's not cheap though fella!

 

[jhot80]

Engine is up and running. I have a water leak that I traced to fitting the wrong bolt in the thermostat housing and the injection pump wasn't running when it had 12v at the connector. Stuck it on the battery and the pump ran. Examined the connector more closely and one of the pins had become dislodged. Turned it over and it ran firsts time Although i haven't got round the reconnecting the exhaust yet so a bit noisy. The new engine is much smoother then the old one not sure if that's down to the different head or maybe the timing was slightly out before.

 

[Ph1 Tom]

Good news

 

[jhot80]

well it has been a long winter (into summer) of going some old steps but it has been worth it.

The sills on the xr2 are the original ones and i knew they maybe a bit frilly and as such had planned to replace them this winter. While Im at it i may as well replace the front floors because they have been replaced before (not me) and it annoys me as its not a good repair.

Got an opportunity for help from a friend with a good unit and a lot of experience.

started on the front inner wing as it wasn't great.

cut back to good metal

part repair

 

[jhot80]

full repair

next was to take the sills off

the more we took off the worse it looked.

started going back together

 

[jhot80]

as the rear chassis rail is pretty much none existent i need to have the bit made as it too complicated a shape for me to hammer out in the unit.

While we waited for that to come back the sheet metal shop. I got on with a few other bits i wanted to do while I'm in the warm and dry.
new door cards

Moved the brake res pots

http://s157.photobucket.com/user/jhot80/media/20150310_184019_zpsmoptqkw3.jpg.html

 

[jhot80]

Been a busy month getting the fiesta sorted. Not there yet but it wont be too much longer now. I hope.

Fitted a new bearing in the steering column as old one was virtually none existent.

That with the stiffened column bracket the wheel barely moves now.

Drivers side is now all welded.

 

[jhot80]

On to the passenger side.

 

[jhot80]

Fitted some seat rails.

Put some hard fuel lines in that dont hug the exhaust or risk dragging on the ground.

 

[jhot80]

Undersealed the car.

New fuel tank as the old one had split on the seam. means it shouldnt be that bad on fuel now.

Mounted the pedal box on a platform make it more comfortable on my feet and once the posts are made the heel plate will give me something to rest my feet on.

Test fitted everything to make sure there isnt anything else i need to do before i start prepping for paint.

 

[jhot80]

Had a little sit in the car and made the customary brooooom pssst noises.

Might need to chop away some of the dash so i can change between the throttle and brake without issue.

The passenger seat was recovered badly before i bought it and it was starting to upset me. It is a Carbon shell seat and would be an arm and a leg to buy a new one the same so i set about recovering it myself. I think it came out really well.

Thats where i am up to now. i hope it wont be too much longer till it back to a driving state.

 

[jhot80]

Managed to the gearstick tower finished

Just the heel plate mounts to go and the inside can be prepped for paint.

Completed the fuel lines under the car.

[/quote]

 

[Advikaz]

Great work mate

 

[jhot80]

The car is still coming along but work has been taking away time from my hobbies and its not racing season and so that has been taking a lot of time as well.

Plus it is at the point where i need to paint and it is so boring and time consuming that i really struggle for motivation but its getting there.

Engine bay is ready for paint.

i put a coat of primer on it last night before i put it away for the evening.

I think i'm going to us POR 15 for the interior and that just leaves me the bay and sills to sort out. should take too much longer i hope then the car can start coming back together so i can use it.

 

[jhot80]

Finally making some good progress with the XR2 now.

I made up a small tent to spray the fiesta in.

Got cracking

Left it for a few days to go off. Then rolled it out.

Painted the inside with POR15 as well and it came out really well. Not as good at 2k spray but on par with rattle cans.

 

[jhot80]

Although the stuff doesnt come off your hands. In the end i have to get baking soda and water soak my hands in that for 20mins then scrap it off.

There is a bit of wet sanding to do on the outside and then its time to reassemble it.

 

[Al_G]

Fantastic!

Well done.

 

[Scrooge]

Properly love it!!

 

[Ph1 Tom]

Making good progress on the welding and you've done a great job on that seat you had off me. Are you still using the paint as well?

Wish I'd have been able to store my blue pop somewhere. That was such a mint shell.

 

[jhot80]

Making good progress on the welding and you've done a great job on that seat you had off me. Are you still using the paint as well?

Wish I'd have been able to store my blue pop somewhere. That was such a mint shell.

No somewhere in the move from my parents shed to the unit i lost the paint. I got some mixed up to match by a coachworks near the unit.
Yer im well happy with how the seat came out. Makes the drives look really tatty now. Need to do the drivers seat but that can wait til its a car again.

 

[Ph1 Tom]

I do love diamond white. I prefer it to a lot of the more modern shades of white. Diamond is a classic!

 

[jhot80]

Its been a while since i last updated the thread.

I have actually done a lot since but just haven't put it on to the site.

During the car going back together and digging out all the engine parts i noticed in what a bad state the exhaust manifold is in. I also noticed that there was bits of the internal weld missing presumed eat by the engine that shat itself last summer and prob the root cause of the failure.

So out can the CAD software and general idea hatched.

bit of fab

 

[jhot80]

much messing around and head scratching later

Finally the fully welded product

Fitted

My friend came by the unit for a 80s flash back picture

Next up was a more robust turbo. The td04 has had a number of issues. Most being related to overheating and bit of a bit on the small side for the power output i want.

next us is a td05h. its a bit on the big side but it still responds quite well.
Whole car reassembled and running ok.

Next up i swapped the odd seats for a pair of corbeau club sport seats. 2 reason thy're brand new and they're xl and it will stop my passengers complaining about how tight the seat is.

as the new turbo has a 90 on that points at the bonnet i got a spare housing and cut it up.

 

[jhot80]

so now it faces forward to give a good routing for the air filter hose.

Next up was the steering wheel that was close to the drivers window that to me.

There has been a lot in between all that as but as a quick summary that covers most of it. Nobody is really interested in wiring changes and p cliping bits to body.

 

[Ph1 Tom]

I would have thought a td05 on a 1.7 would be laggy as hell. TD04HL would easily make more power than you could want.

 

[s.mac]

Great cars and I wish I'd have kept mine , keep up the good work

 

[jhot80]

I would have thought a td05 on a 1.7 would be laggy as hell. TD04HL would easily make more power than you could want.

Na not really. Td04 came on boost around 2.3k but would fade long before 7k rev limit and would make the power i want but it would be going be what it supposed to do and although it would make the numbers its wouldnt be as quick and would put more stain on the motor for the same power.

The td05 comes on a out 3k but just keeps going all the way to the rev limit and will make much more power for the same boost or less.

The td05 is also much more robust than the td04. The td05 has a much large water jacket and as it isnt being pushed pushed over passed the oem standard boost so should be nice and reliable

 

[jhot80]

Trying to push on with getting the fiesta ready for trackdays when the weather improves.

The main thing i want to get done is a better radiator and charge cooler rad set up. At the moment i have a Saxo VTS rad and i dont like it. It is really hard to bleed and the header tank mounted on the side well below the height of the turbo. With the new turbo is clears the space where the original header tank went.

The plan is to put an original header tank in and use a 'rad pack' with the new ally rad sitting in the standard mounts and the charge cooler rad bolting to the front of it. The rad will sit better into the front panel than the current one giving more space for a good fan cowling to help. Like below.

I managed to get hold of a brand new fiesta header tank.

That looks like it made to be there.

Im just waiting on a guy to make my new rads then its off to the mappers.

While im waiting for the rad i have been blasting my spare set of wheels ready for me to paint them. Ive done 4 of them now. Just need to paint them and then get the Avon ZZRs on them.

 

[Iain C]

Amazing job fella. Been a long project!