fiestaturbo.com

[THEHOG~]

well the pully bolt is removed, surely it just come off with some determination,then remove the bracket around it?

i think i need to use a pulley puller but the one i have it 2 big, i am going to use a new pump just in case, dont want to get it all done and all of a sudden come to a stop becase the oil pump packed in a seized my engine tight

[jonyb4]

sorry to hear your getting rid mate, but when you cant afford it, you cant

[THEHOG~]

Yea its a bit of a sickner, but means must i dont think this will be the end for me and the fez as i hope to sell it to some one i can stay in contact with maybe some one on here or fiesta si, this way if the car come back up for sale later down the line i will still be in contact to make an offer for it.

i have a friend that is getting really good with his welding skills and we have been talking about a trick conversion on a fiesta.
we are thinking of a 4WD cosworth convert ion but i am very hazy on how it is done so far i know i need the inner wings and the transmission tunnel but i presume i would need the bulk head or to make a custom one and cross members.

Does any 1 know were i could get some more info on this conversation as we are quite keep to start planning this and if we can get the 2 Donner cars we would be ready to start it, at a slow pace of course due to money issues ?????

[HCS PIMP]

why dont you just rebuild the bear berry fez and sell it ??? its got some awesome spec and we both know how it drives

0-100mph in 10 secs would quater mile in 13 sec i recon with the way the engine was running before that maf started playing hell

plus what did u do with the old block ect could have just sold them

i would still be tempted to buy it back if u can put it back to how it was ???

[jonyb4]

10secs???

[Ratspeed]

10secs???

f**k off man, his mates down the pub say its well fast

[jonyb4]

[HCS PIMP]

couldnt be the fact i dynoed it after i converted it and the fact it ran 0-100mph in 10 secs.
yes that was without the air resistance or the load of pulling the car but on a 1.6 box they hall ass
Tbh i don't understand what people gain from being over critical on this site but alot of time and effort went into this car i should know i bought it as a standard fez in gr8 nick
got the right parts for it but i knew i was responsible enough to own a car with that much power at 20 so i sold it and the hog got a very good car
I understand if he doesnt want to part with it took me long enough to decided but i will have another 2.0 fez before too long
and when im finished money permitting that and the misses ill show people what i can achieve untill then i suppose i may be a keyboard warrior

sorry for thread stealing hog

[Ratspeed]

Aww, bless ya

[jonyb4]

llama what you going off on a rant for, most that werent even relevant lol

100 in 10secs on a dyno?
bet your mighty proud

[THEHOG~]

why dont you just rebuild the bear berry fez and sell it ??? its got some awesome spec and we both know how it drives

0-100mph in 10 secs would quater mile in 13 sec i recon with the way the engine was running before that maf started playing hell

plus what did u do with the old block ect could have just sold them

i would still be tempted to buy it back if u can put it back to how it was ???

I vouch for the engine being quick but as for the well built part I think you have got your self a bit deluded there mate.
If you look back on the tread the hole reason I am in this bloody position with the car is that some gammon slipper could not put the fly wheel bolts in properly I mean come on if a bolt is not going in the last thing you want to do it force it in, and in doing that he f**cked the threads for at least 3 flywheel bolts and I mean threaded them to f**k there was no way they could be saved.

Then there is the s**t job on the water pump which later exploded its gasket and was pissing water all over which in turn cooked the engine along with the oil seals the lot.

I have no complaint about the rest of the car hey it was top work as far as the rest goes but that engine was far from well built.

When I thought about getting a fez si I decided to just buy one with the engine already in and pay top notes for one so I would get a good one that and I did not have the skills to do a engine conversion, But I may as well have bought a 1.6si and done it my self as I have had to do it anyway.

After all this carry on it will be the last time I ever buy another persons work from now on I will buy standard and built it up my self.
To be honest the only good thing that has came of it all for me is the fact that now I can pretty much do any job on pretty much any car now as I have been doing to get some extra cash for the fez.

As for the engine block I still have them but they may be getting used in a ZETEC turbo CATERHAM.

As for the fez its progressed a bit apprentice money and lack of time and moving house has left the fez on the back seat a little but progress has been slow but steady which is better than no progress at all.

so far all wiring is back in same with the interior, rust has been taken care of bar one spot on the sill which i will get to soon, the second engine has been built up and its pretty much ready to go in the car but I have to wait two weeks for my engine hoist to be delivered to my home.

Some random pics that were on my camera I have more but cant find them.

[THEHOG~]

[jonyb4]

good progress mate

[HCS PIMP]

I agree the water pump gasket wash shat this was due to the original gasket tearing so i had to use instant gasket
the flywheel was fitted by a mate of mine kev who since threading that went on to kill a classic mini engine

so yeh sorry about those 2 things

still a mint car tho id love them h&rs and the cossy brakes
probs gonna have to buy another set for my new project

[THEHOG~]

so that's why the pump failed ok well that's a wight of my mind.
Now I am certain I should have no problems with the pump now.

And the cossy calipers are sweet now they have braided lines in but they could do with a better servo from the mondeo as there a bit sponge still I may install one before I put the engine in next week if I can get one for a good price at the salvage yard.

My main fear is getting it all back together and running to find that I still have that weird power cut problem going on as I never managed to get it sorted before it all went wrong.

I think its somthing to do with the wiring some were inside the car as I would here a click sound from inside the car as the power cut out and it was a total power loss as the clock reset and same deal with ECU but I have looked at all the fuses and non are blown which would then suggest that there is a live shorting out or somthing.

But I will have solve that one when its running.

So far today I have just been sorting out rust in the car there are a few common places starting to rust, I have 2 spots on the door starting, a spot on the boot and on the lower part of the wheel arches are starting there not bad or anything I just like to take care of things like this sooner rather than later.

Soon I am going to turn my attention to the paint work and get it looking good again.

[THEHOG~]

Also painted my rear drums too

[THEHOG~]

Done a few little bits on the engine today.

Cleaned the top cover gasket mating surface I used my dremel with a polishing head attachment and it worked a treat cleaned the surface up nice and smooth.






Don't worry about the bits of crap that is around the tappets as I will give it a run over with an air compressor and then when I have the engine finished I will run some old oil through the engine and drain it out to flush the engine out before I put in the new oil.

Also give the port entrances a file down and then used the dremal to clean it out as they had a lot of carbon build up.



Fitted one of the cams from my old engine as I stupidly cracked the end of one of the cams.





The broken cam.




I was going to use both cams from the old engine but on inspecting them I found a dink in it so I decided not to use it in case it through the balance of the cam out not sure if it would or not but I rather be safe than sorry.



also can anyone help me I have forgot which way the hoses plug into the steering rack for the power steering.



Does this one go in the top hole or bottom lol ??



same with this lol

[jonyb4]

what you confused on mate?

resevour end is two thick hoses that are clipped on using spring/jubilee clips, one going to the pump has spiral plastic sleaves for protection and a silver heat shield and its a near U shape
the other goes to the radaitor/cooler and has a jubilee clip but is alot thinner than the tank-pump pipe

then the other pipe fromt he rad/cooler is long and bend 90 degrees at the end with a solid joiner which attatches to the rack, other pipe goes up to top of the engine it has plastic sleaves liek before and has the sensor and bend in it, the other connects to it at the top of the engine and goes back down to the pump secured at the dipstick clamp near the exhaust manifold

[FiestaBen]

And I thought the oil pick up pipe on mine was big

Good work mate, will all be worth it when it's finished

[THEHOG~]

Thanks guys.

yea I was surprised at the size differnce between them.

@ jony I am confused on where they bolt into the steering rack does the pipe with the sensor go in the top hole or the bottom hole in the steering rack ?, I am not sure if it even matters but I would rather be safe than sorry lol.

I took pics of every part I took off the car but I have lost loads of them due to a crashed computer which is a shame as I wanted to make a usb stick portfolio kind of thing of all the work that had been done for the new owner.

Quite frankly I hate small car with PAS if I kept the car that is one of the 1st things going in the bin and a manual rack in its place.

[HCS PIMP]

ive still got all my pics from the work i did

[THEHOG~]

I pretty much have all the vital pic I need just one or two I am missing I am way to disorganised lol.

Few little bits done today.

Fitted the cam pulley.



Rebuilt the injector rail and replaced a few of the injectors with the ones from my 1st engine as a 2 were damaged.






Replaced the timing belt guide wheels on the water pump as one has a sharp gink in it and the other had a crack in it to I swapped them for the wheels the were on the 2 litre water pump.






I decided to give it all a good clean around the pumps so no oil gets on the timing belt.



Also had a problem fitting the timing belt as it looks like it is the wrong size or has too little teeth I dont know but I wont go over the other cam.

[xr2irhys]

check the tentioner , this will give u the little play to be able to slip the belt on..

[THEHOG~]

[quote="xr2irhys"]check the tentioner , this will give u the little play to be able to slip the belt on..[/quote

Na I had it as slack as I could get it.
I think its deffo the wrong belt its either the 1.6 belt or a black top belt as there just is not the right amount of slack to get the belt on and even when you get it just about there the teeth will not line up on one of the cams

So it looks like another delay in work until next week when pay day comes.

so far I need to get a:

timing belt
AUX belt
throttle body gasket
2nd inlet gasket
manifold gasket
thermostat gasket
a flexi pipe for the Ashely
fluids all round
a pair of sun visors
Inlet bolts as I seem to have miss placed mine in the sea of car parts that is my life lol
new battery as the old one is pissing out acid
track rod end
pair of wish bones.
and some new wiper blades

So my bank balance is in for a kicking lol.

[jonyb4]

haha big list, a funlist though, all easy fun jobs, most of its cheap as chips too

my favorite one is the new inlet bolts, shiny

i swear the 1.6 is identical outside to the 1.8 and 2.0 so belt would be exsactly the same surely?

[HCS PIMP]

1.6 1.8 and 2.0 all the same belt im 90% sure the blacktop is the same only revised tensioner design

[THEHOG~]

well I am stumped as it will not go on the engine its way to tight to go on even if I managed to get it on by some miracle it would only last 5 mins before it snapped and that is with the tension slackened as much as possible I even called my mate that is a mechanic for a second opinion and he said the same as me.
Thing is I through the old belt away stupidly so now I cannot compare the two lol.

Decided to hack up the original SI inlet rubber pipe to make some spacers so I could fit the RST inlet pipe to the MAF/TB.
Its not the best job but it will do its totally sealed and looks fairly neat so it will do the job.

Cut a thin strip for the end of the inlet that goes to the TB that then made the pipe fatter so the rubber adapter would fit and be air tight.



Done the MAF side of the pipe the same but made it fatter by using electrical tape to make it fatter for the adaptor usually I would not do this but with it being on the cooler side of the pipe it dont mind.






It all works perfect so I am happy I still have to clean it up and block of the pipe holes altho I may use one of then for the cam case breather pipe and I need to see if I can bolt it to the rocker cover with out the cams hitting the bolt heads.
All in all it will be way better than the standard inlet and the K&N banana pipe which starts to melt on the bonnet on hot days lol.

I love for I really do and I love the zetec engine but I cant figure out why they routed the inlet over the top of the engine lol.

[jonyb4]

then why dont you try the plastic later spec manifold, the 1.8 escort would would fit easy, or a focus 2.0 one even, more air flow than the HO inlet even and colder

think the focus 2.0l one needs some hacking first though

[THEHOG~]

I was going to put on a escort inlet if I kept it but there is not much point now its going and if kept it it would have had TB'S and custom management at one point.

[D9LSY]

right Hoggy get it finished and flicked into the bay

Good progress sir

[MB7201]

You are doing the cambelt wrong, the cam pulleys should be undone so they can rotate. You have to line the bottom pulley up, lock the cams from the bar, put the tensioner in place and then do the pulleys back up. You should undo/tighten the pulley with a tool to hold the cams still so it doesn't snap the end off.

[THEHOG~]

hey MB thanks for that I was sure it had to be somthing i was doing wrong I will give that a try today mate I hope it is that as I cant do any more progress with any part of the car until I get this timing belt done.

Hi dalsy mate yea shouldn't take me too long to have it back now I have my engine hoist coming I am still gutted I wont get it to the spec I had planned but you live and learn and I can put what I have learned into my next car once I am making proper money.
But after it is sold I am going to buy a cheap to run car either a mk3 or 4 1 to 1.3 litre fiesta or a ford ka and use my money to build up my tools so when I am making better money and can afford another project I will have a good arsenal of tools behind me to do what I want.

[MB7201]

Thats alright, just to make sure you need to hold the camshaft (and not by the locking tool) to undo them. I think there is a flat on the cams where a spanner can be used, but a pulley holding tool is recommended. I'd suggest initially undoing the pulley bolts without the bar in place to avoid putting pressure on the cams and damaging them. Nip the bolts back up so you can rotate the cams into their correct position, put the locking bar back in and then undo the bolts again.

[THEHOG~]

Thats alright, just to make sure you need to hold the camshaft (and not by the locking tool) to undo them. I think there is a flat on the cams where a spanner can be used, but a pulley holding tool is recommended. I'd suggest initially undoing the pulley bolts without the bar in place to avoid putting pressure on the cams and damaging them. Nip the bolts back up so you can rotate the cams into their correct position, put the locking bar back in and then undo the bolts again.

Thanks mate you were spot on it slipped on there no bother.
I managed to get one pulley lose using a screwdriver to jam the pulley but I cant get the other one off using the same method and one side of the belt is still a little loose so I will need to get a holding tool asap before I can finish it.
Thanks again mate.

[jonyb4]

Thats alright, just to make sure you need to hold the camshaft (and not by the locking tool) to undo them. I think there is a flat on the cams where a spanner can be used, but a pulley holding tool is recommended. I'd suggest initially undoing the pulley bolts without the bar in place to avoid putting pressure on the cams and damaging them

spot on mate

although since i was also lacking this tool, i wedged a few screw drivers/chisels inbetween head and spokes of the pully, not ideal but it holds up to the 85NM (if i recall right) it takes to tighten the bolts holding the pullies on

why not get a mk3 1.4 Si mate? cheap tax to run and insurance, yets till somewhat sporty and good looking



dalsy i seen a 'thanks to' bit from Niel in fast ford's 'the fleet' today on niels track car, nice mate your few words of fame for me