1986 Ford Fiesta XR2 1.7 VVT Turbo

[jhot80]

Finally got my wheels finished. They have come up quite well.

I have also finished up making the new boost pipes. they just need me to brush them up.

Tidied up the label for all the switches on the dashboard.
Before

After

I kinda just doing faffy bits while waiting for the new radiators.

 

[RMDavis]

I bloody love this car!

This is another one of those 'project' threads that have gone under the radar!

Need to see some videos of this once its running.

 

[theburns1]

No way, use to enjoy reading your updates on xrtwo lol. Looking good mate

 

[jhot80]

I havent updated the thread for sometime but i have been busy on the car. While i am waiting for the second radiator core to turn up so i can have the rads made i got bought and hatched a plan for a new engine. as you do.

This one is a 1.6 not a 1.7.
The engine that is in the bay at the moment would max at 200bhp while keep the durability sensible. The new engine will be able to go to 250bhp if required and be durable at that for sometime.

I just need to get round to take the old engine out of the bay. Its ready to crane out when i get round to it.

Also the sunroof has been a concern of mine for sometime. its a bit rotten around the edges and leaks making cleaning the car a pain or driving is in bad weather. While i would like to get a carbon roof at some point i wont be doing it now and the roof would only get worse. On that note i get the CAD out and measured up for a ally panel to replace the sunroof and got it lasered.

Then the point of now return.

The offending item.

and the replacement panel in and sealed up.

It was riveting work.

 

[massiveCoRbyn]

Such a cool project this!

 

[jhot80]

Whilst Preping the old engine to come out i took off the main fuel line that feeds the fuel pump and found that it had kinked and split i dont think it was leaking but would explain when i started to wind up the boost it would misfire most likely because the hose wouldnt let the pump pull enough fuel through. I have now moved the swirl pot so that the feed for the pump is just in a straight line.

Next on my list was the idler pulley bracket for the new engine and new lightweight alternator. I had a few bits lasered out.

Folded the edges a bit.

Welded.

Fitted with pulley and ready to go.

After that the engine was was ready to go in. and so the old one needed to come out.

While the engine us out a bit of wiring tidy.

Then the new engine needs to go in.

That it is literally just hanging on its mounts at the moment. I need to tidy up as the workshop is a state where i was rushing to get it all in before i had to go home.

 

[jhot80]

The last few bits for the new engine are almost there now.

All of the electrical changes needed are now done. I contacted to pace to find out where the core for my new rad is as it still needs to have the end cans fab'd once i get the cores. It is being leaked checked today and then posted out.

I made a little boss and bung to use for the dipstick as the new bottom end/sump the dipstick runs through the block but on a puma engine there is an external dipstick tube. I have put it in the cam cover which means i cannot leave it in there when the engine is running but its not a problem.

Just need to tig that with a few other bits and then remaining bits can be connected fill it with fluids and once the rads are here fire it up, see how it runs.

 

[CageyJ0nnY]

its amazing to read through this whole thing, its come so far!

Brilliant work mate.

 

[jhot80]

After a looooooooooooooong a 2 week wait for Pace Products to make the small radiator core for the charge cooler. I then had a another 4 weeks to wait for the main rad core to be made. 5 weeks later I called them to find out where the core is and how long it will take. The guy said there had been a mix up with a sub supplier and it would be another 6 weeks.... exactly the lead time for a new one to be made almost like it got forgotten after the small one was made hmmm. Anyway they had a look round the stock found one that was a slight thicker core but the right height and width and would post it out that day after a leak test... another week rolls by and no core. Phoned up Pace again and turns out it got sent to a customer in Germany for some reason not to me. Lucky they had another one on the shelf and it turned up the next day. 8 weeks from pacing the order to delivery. To be fair they quoted 6 weeks and they were very helpful once they realised their mistake.

So for the pics of the main core and they are very good.

Tacked the main rad together with the fan mount.

and the 2 rads together fully welded.

Now i just need to polish them up so they look a presentable and then get them the car back together and finally start the new engine.

 

[jhot80]

The rad is now in and plumbed in.

im really happy with how it came out.

 

[Cookson]

Any reason you went for the 1.6 than the 2.0?

 

[Advikaz]

Cool!

 

[jhot80]

Any reason you went for the 1.6 than the 2.0?

2.0 Zetec is a lot heavier engine. Wouldnt make for good weight balance.

 

[jhot80]

I have done a lot of work in recent months. Getting the new engine running has been quite a bit of agg. The engine has a 60-2 trigger wheel mounted to the aux belt pulley they has a lot of magnets set in plastic that is an interference fit with the crank, which is where all my issue has come from in trying to get the tdc synced with ECU.

In the end I gave up with the fead mounted trigger and drilled the engine block so i could use a nice hall effect sensor picking up on the flywheel trigger wheel.

i stuck some rough starting numbers in to get it to start and it fired up straight away but after a lot of faffing with this ECU i seen a lot of things that really annoyed me about it. It isnt capable of controlling the VVT properly at most on/off switch, doesnt have any proper boost control, there isn't a specific cranking mode for making starting fast and it isnt capable of controlling the idle beyond manual adjustment of the fuel and spark in the idle speed range, which is variable depending on the ambient and engine conditions.

These has been bothering me for a while but the final straw was the difficultly it gave me when i was trying to make it start with the 60-2 trigger. Soooooo i went out and bought this.

Adaptronic E420d has all the features that I need now to make the car run well all the time.

Then began 'the re-wire'

IAT Sensor

Inlet Manifold Sub Loom

 

[jhot80]

Coil Pack Sub Loom

Just waiting on the coil pack mounting plate to be laser cut.

That was most of the engine bay wiring complete.
It was then a lot of labelling and cutting the old ecu off.

I wanted to tidy up my switch wiring while it was all apart. I have had a few occasion of having to trace the wires to remember which switch they attach to.

 

[jhot80]

Slowly but surely things were getting there.

and it was there.

New idle control valve.

Clutch pedal switch that will replace the banjo bolt that is current on the clutch master cylinder.

Then came for first start and i couldnt get a rpm readout. I did a load of fault finding on the wiring and discovered nothing wrong. I think played with the settings and got the rpm readout but it wouldn't start. This started the long back and forth between me and adaptronic, who have been VERY helpful, basically because i am now coil on plug, seq injection and want close loop VVT control i need to use the cam phase sensor. The puma engine has the same weird 8-1-1-1 trigger on the cam as the st170 which no other oem has ever put on their engine and Ford hasnt done it since this 2 engines. i have take an oscilloscope measurement of the engine to help them.

This has been a long process as adaptronic are based in Aus but they are in the process of updating the firmware so the ecu can work with this trigger but i went down to the workshop this morning with some software that adaptronic have sent me in and it is running. I am quite happy that i chose to use the adaptronic as their customer service has been faultless and other ecu manufacturers might have been asking me to pay them to make this update.

It has been a long time coming and cannot wait to get it out of the workshop and shaking it down before mapping.