fiestaturbo.com

[jonyb4]

The brake servo was off a mk5 escort you will also need the vac pipe too, unless you want to bend your old one, the master cylinder was of a mk1 mondeo as the outlets on the mondeo matched my compensators, if you got any probs with stiffness it defitanly helps

i beleive the mk1/2 mondeo servo and master cyl is a direct fit also, saves mixing parts and looking harder

[shaunrs]

Has anybody ever done this to there gearbox cradle lol, 250 ftlbs of torque

[andymcd]

looks like you launched it pretty hard? only reason i could see it doing that? is the gearbox broke?

[jonyb4]

cant work out whats going on in that pic

[RS rob]

looks like you've been driving it hard there,
the zetec gearbox cradle is reinforced a bit more

what mounts are you running on the gearbox
and what mounts do you have on the engine side?

[heeman10]

Brute I did make up some fairly meaty reinforcement plates to prevent that! They never pulled through, so clearly did the trick Mikee did this too, with his 2.1 ZT, and a couple of others have had this issue.

[RS rob]

well my plan is to have vibratechnic gearbox mounts on the cradle
got a brand new rear engine mount and the best second hand condition front engine mount

i think that should help even out the engine movement strain, rather than it all just pulling on the gearbox cradle like yours

[- Danny Boy -]

Yeah I had that on my old car actually lol. Execpt yours looks worse lol.

[SLEEMAN]

bloody hell never seen a cradle do that but! best to get a new one!! and possibly reinforce it by welding some metal around the mount??

[shaunrs]

Well ive been working on for a few hours today and ive decided to repair it, and then beef it up with lots of weld and a bigger washer, then a couple of coats of satin black.
Took it out for a spin once sorted! subarau up my arse then left him for dust lol, he looked very shocked

[jonyb4]

hah nice one, i love hearing that happen, stupid big cars thinking theyre the shiz

[heeman10]

That engine has left many an Impreza for dead Shaun, I'm glad you're keeping up the tradition

Have you welded a plate on the inside of the cradle? I can't see a great deal of strengthening there, and the washer doesn't look particularly meaty or large. Did you get away without damaging the bonnet the first time? It would be a shame if it happened again and the bonnet got damaged.

[shaunrs]

Why the hell does my car rev over 2000rpm until the water temp reaches 90c and hunts like a little Bic™ when warm and does about 10 too the gallon, People must think why is that man reving his car like that lol, it does my nut in
Things ive tried.
map sensor
checked air leaks
new water temp sender
second hand iscv
The only other thing i can think of is the mapping, any help would be great thanks

[heeman10]

The engine always did idle a LITTLE on the high side from cold, but TBH I see it as a really useful way to warm it up from cold start. It drops to where it should be when the coolant temperature picks up a bit. As for the revving and poor economy, that is not the mapping, it sounds like you have a mechanical issue of some kind. That engine managed the 300 mile drive from my house in Cumbria, all the way to Somerset, on a single tank. Similarly, I think the worst I ever got was about 140 miles on a tank with hard use, so if you're only getting 10mpg on a combined drive of sorts, something is amiss.

Have you already had it on a rolling road to check it over now? I seem to remember recommending that when you were about finished installing the engine, as a rolling road set-up/checkover ensures that everything is set where it should be, and that you're not going to damage anything by using it without KNOWING that it's healthy before you drop the hammer.

[shaunrs]

Hello james, it does idle high over 2000 rmp when cold, i cant find any signs of air leaks unless its inlet manifold side of things. i find it a bit of a bugger on the clutch control. and mpg is very low atm. But ive disconnected the idle control valve for now so i get a nice low idle 500rmp-750 still hunting though
Ive not had it on the roller yet mate, ive getting it booked in to msd shortly, i sure they will find the problem and charge me a fortune

[heeman10]

I'm sure they will find the issue. It was MSD who mapped it, so if you want the cold idle bringing down a bit, they could do that for you, for a price.

[fiesta boy]

shaurn pm me ur number lost phone lol so no replys

[shaunrs]

This couldnt have happened at a worse time for me but my engine has given up, basicily my engine started to breath very heavily so i did a compression test and i was down 70psi on cylinder 3. Time for a strip down and i discoverd this! 2.1 is calling my name
So i started stripping.

[jonyb4]

how on earth did it do that?

which pistons are they?

[- Danny Boy -]

Oooooooo not good! Best get checking all the shells too, make sure nothing has gone into them either, last thing you want is the cost of replacing the crank. Bad times.

As said, any idea as to what the cause was?

[Rhinopower]

They are standard cast 1.8 pistons

[shaunrs]

Yes stock pistons, i had the engine off heeman. The only way this could of happend is rise of inlet temps, msd checked it over about 3 weeks ago and all was fine so im very confused why this has happend, so the car wont be making it down to central day sunday

[fiesta boy]

told you mine would be on the road before yours lol see you in 5 ugly

[heeman10]

That's not good news What have your inlet temps been while you've had it? From what I can see, your intercooler is completely hidden behind the bumper, and IIRC is also mildly under-sized. Unfortunately, that is a recipe for high charge temps, which are always less than desirable. Were you revving it hard? The cast pistons were never intended to be abused in the same way that forged pistons can be, and they held on admirably for the 15,000 miles I covered with them. Maybe forged pistons will suit your wishes better!

[fiesta boy]

cvh the way forward

[shaunrs]

finaly got a donar engine, 2.0 mondeo had 106000 on the clock, they gas axed it out and chucked on the van lol got it for a cracking price




Spent a few hours tonight stripping the unwanted etc

[fiesta boy]

nice hoist and chains wonder wher ther from lol call me

[shaunrs]

nice hoist and chains wonder wher ther from lol call me

I think the hoist was from machine mart mate, they sell a range of things!

[zanderford]

c'mon get it done i need some more motivation

[niracka]

Just read this whole thread and Its a really lovely car buddy. Such a shame about the engine. Were the pistons machined down from standard??? Take it your going to go with c20let pistons and the slight overbore this time???

Keep the updates coming.

[heeman10]

Pistons were left un-machined, retaining as much material as possible. Compression ratio was lowered to approx. 7.9:1 by use of a decompression plate. Engine was then mapped by MSD in 2005, and went on to complete a great deal of miles. The engine only had 8,000 miles on it from new when it was converted into a turbocharged setup, so it was barely over the 20,000 mile mark when it met its end.

[niracka]

So there must have been something wrong to cause that then. Even with the pistons machined on the 1.8 they are still capable of holding good boost.

[shaunrs]

So there must have been something wrong to cause that then. Even with the pistons machined on the 1.8 they are still capable of holding good boost.

When the head was taken off there was a lot of slop in those bores, as you can imagine the skirt of the piston as took the hit, if you look closely on all the pistons you will see the where the slop has rubbed on the skirts.

[shaunrs]

c'mon get it done i need some more motivation

Pull your finger out

[shaunrs]

Had a very good day on it today, took it very steady, not rushed and got more done than i thought.

i drilled and tapped two breathers in the rear of the block, we all have to breath


Then a little spruce up