fiestaturbo.com

[Max M4X WW]

Sounds like any other ZT really, but..

[Dave5300]

Epic

[Turboboy67]

I'm glad it's finally all come together bud, I love the look of it

[Max M4X WW]

Well its nearly Ford Fair, so thought I better get on with cleaning the car!

If anyone is interested, process was as follows..

Clean around trim etc with AutoSmart G101 and soft brush
Wash car with shampoo, cant remember what (bit of G101 in this too)
Iron-X applied to the whole car to remove metal fallout (mostly from my bonnet catch fitting, but the rear was bad too! see pics)
Rinse and go over the whole car with Bilt Hamber clay (I didn't use any de-tar products prior to claying as this was done before it came off the road)

This left the paintwork nice and smooth so the next day we went over the car with a DA and a Menzerna compound which has left a pretty good finish for now. Waxing, bumpers, trim, tyres etc and engine bay still to do!

We the fitted my freshly painted roof rails, new door weather strips and I have new washer jets to go on!

[FRSJON]

damn max that looks lovely..i must get another red one !

[Excursion]

Awesome work

[Max M4X WW]

Bad news today, took it to Surrey Rolling Road to have the fuelling checked. It's not been run for 5 years as you know and spec wise the only thing that is different is the intercooler. With the amal unplugged and by-passed it was hitting 8psi but running very lean. I had a feeling it was, as there wasn't much noise on over-run! So I will be ringing Grove Garage Monday to get them to look at it.

Made 147bhp and 170lbft at about 4500rpm though

[FRS_Steve]

Looking nice, shame it's running lean but I'm sure there's plenty more to come when its set up properly!

[Rhinopower]

Should have the amal connected if that what it had before, i believe it could stop it from being so lean!

[heeman10]

It came up an absolute treat! Looks great

How lean are we talking? Have the injectors been serviced in those 5+ years? Fuel pressure/CO pot set up right?

[Max M4X WW]

Should have the amal connected if that what it had before, i believe it could stop it from being so lean!

I thought it controlled boost only? I have no idea, just saying!

How lean are we talking? Have the injectors been serviced in those 5+ years? Fuel pressure/CO pot set up right?

I've done nothing to it, no idea what the fuel pressure is and I've not touched the CO!

Means nothing to me..

[Rhinopower]

The Amal valve controls boost, but it can also make it make less boost. In that case it would be richer.

[Max M4X WW]

It can't make less than 8psi though?

[Excursion]

8 PSI will be the boost set at the wastegate, and if the car was mapped with an amal valve it won't correspond to your max boost. The amal bleeds off air so that the actuator doesn't see whatever it needs to fully open - this way you can get a better curve and build boost early.

I never understand why people take them off and go back to setting boost via preload on the actuator, as it's a step backward. Plug it back in mate.

[Max M4X WW]

I understand that, but Grove Garage had it set up for Mikee with a switchable amal for low/high boost so it's no different being switched or disconnected?

[Excursion]

I understand that, but Grove Garage had it set up for Mikee with a switchable amal for low/high boost so it's no different being switched or disconnected?

What boost do you have with it plugged in?

I'm pretty sure the Amal has a restriction in one of its ports, and in that case removing it altogether would not the same as running direct.

[Max M4X WW]

I'm not sure with it connected as I've not tried it but it was supposed to be 20psi or so.

[Max M4X WW]

Well it made it to Silverstone and back, didn't seem to struggle in the traffic on the way back either!

My main problems are the mapping that needs doing, the volume of the exhaust and my constantly moving and sticking biting point!

Thanks to those who voted for the car as car of the stand

[Max M4X WW]

I forgot to also mention that my (power assisted) steering seems to turn right easier than left. Its not noticeable when driving really but when parking its really obvious, also when coming off a roundabout as you go from right to left quickly!

[heeman10]

Good on him for aborting the run That is not good. Could be one of many things:

Blocked/faulty injector(s)
Blocked fuel lines
Blocked fuel filter
Failing fuel pump
Incorrectly-adjusted fuel pressure regulator
Incorrectly-adjusted CO pot
Faulty MAP sensor
Excessive boost pressure

It needs to go back on a good dyno with a good operator to find out why it's running so lean. It needs hooking up to a fuel pressure gauge (to be monitored during a few probing runs), and the injector duty cycles need monitoring (during a few probing runs), as does the boost pressure. If it idles at a healthy AFR, maintains correct fuel pressures, and if the AFR stays healthy early on in the rev range/at <25% or so throttle openings, the CO pot is probably still set where it should be.

The next step will be to see what is causing the engine to run lean as throttle openings and/or engine speed increase. If the fuel pressure remains healthy and the boost isn't doing crazy things, the injector duty cycles will tell you whether the problem lies with the MAP sensor (presuming the engine map is dependable and correct) or with the injectors. If the ECU is demanding more fuel, and the fuel pressure is healthy, but the engine starts to run lean, the injectors are either being maxed out or they're not working correctly. If you reach this situation, it'd be time for a clean/servicing of the injectors, or time for a new set of direct replacements.

You get the picture: this needs investigating, because that AFR curve spells a potentially terminal issue at present.

[Max M4X WW]

Thanks for the reply! Sounds like driving it to Silverstone wasn't a great idea but who cares! I won car of the stand

Once I have sorted my head/stud/turbo mounting issue it will be off to Grove Garage.

Blocked/faulty injector(s) - Who knows
Blocked fuel lines - Were ok with the 1.1 but were un-connected for a while
Blocked fuel filter - New Ford
Failing fuel pump - Sounds ok, but who knows
Incorrectly-adjusted fuel pressure regulator - Not touched
Incorrectly-adjusted CO pot - Not touched
Faulty MAP sensor - No idea
Excessive boost pressure - 8psi tops, was set up for 21/10 on dual with a switch on the amal

[heeman10]

Woo!

Let me guess, exhaust manifold studs seeping oil? Bloody ERST manifold "adaptation" mods!!

You can probably rule out the MAP sensor, as the idle would probably be pretty dreadful if that were the case.

Good luck getting to the bottom of the issue

[Max M4X WW]

Yea a couple of them don't have threads any more so it was leaking. I have an adapter plate, but have just found a re-flanged ERST manifold on ebay and I can't decide which to use.

[FRSJON]

none of mine leaked oil id go with the re-flanged manifold as the adapter plate will bring your turbo closer to the rad

[Max M4X WW]

To cut a long story short, the end is near for the ZT under my ownership. One of three things will happen to the car..

1) Sold as is for completion by someone else
2) Broken for parts and the shell sold
3) Broken for parts and the shell retained by myself (if it doesn't sell for a decent price and I can find somewhere to store it)

Various reasons for this really, but here are are a few photos from a random drive last weekend..

[hb69]

What's left to do to complete it?

[Max M4X WW]

General tinkering..

The cooling hoses are routed wrong so if you put a thermostat in it makes the coolant foam up (I didn't know it didn't have a stat in!)
It's only running low boost, needs setting up/mapping really.
The steering is stiffer to turn one way than the other.
The clutch biting point moves around (I think it is the pedal)

Maybe more..

[2105adam]

I may be interested in the car as a whole or my brother certainly would. Please PM a price you have in mind for it. Cheers.


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[Max M4X WW]

PM Sent

[MK4 Rick]

Keep it and fix the problems

[Excursion]

did it disappoint you in the end, Max, or is it just time to move on now you achieved what you wanted to?

WRT the steering, have you tried bleeding it? When stationary hold it on full lock for a minute or so, then the opposite way. Are your strut top bearings OK? Can you jack up the car and turn one way but not the other?

[Max M4X WW]

It's not a disappointment at all, its just not really the car I need at the moment. I don't have access to a garage that I thought I would which doesn't help! I don't have the time to actually 'use it' or go for a drive, so it usually involves taking it shopping or using it when we go for a meal which is fairly pointless..

I will have a look at the steering, but it almost feels like the rack is catching or something. Feels 'elastic' one way and not the other. I will try and bleed it, but it has been driven a fair amount. Does the cap need to be off?

[Excursion]

Makes sense...

No, the cap doesn't need to be off.

BTW - I think you may be missing a thermostat housing bolt

[Max M4X WW]

BTW - I think you may be missing a thermostat housing bolt

I will check in a min, just gone out in it! I've never taken the housing off so not sure.

[2105adam]

Thanks for the PM, it's not letting me reply on my phone. I'll say to my brother and see what he says, cracking car.


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