fiestaturbo.com

[Dave G fsi]

Looking good mark

[Excursion]

The custom pistons have been produced. Ian had quite a bit of working out with these due to the stroke and pin height. They are completely bespoke and weigh just 286 grams! To put that into perspective the piston/ring/pin assembly from a 1999 Ferrari F1 engine weighs 422.4 grams (If my info is correct).

I asked for the skirts to be coated in DLC, Teflon or similar.

[creator]

Very nice mark

[elPaulio]

Mmmmmmm.......shiny!!!!!

[FRSJON]

do i see four rings grooves ?

[D.J]

Looks sweet

seems crazy that something so gorgeous and well engineered will never be seen!!!!!

[Excursion]

Cheers all. They would make a good ornament

Jon - see 'Accumulator Groove': http://www.cp-carrillo.com/Tech/PistonT ... fault.aspx

[freak power]

do i see four rings grooves ?

I see three, JE use this V grove on all there pistons now

[DaveRom]

Looks awesome Mark, I would think the first time you start and drive that it will feel so rewarding.

Y'know what would finish it off though, a flux capacitor. I'm sure they sell them at Maplins, failing that eBay

Hope you're keeping well mate anyway

[Excursion]

Looks awesome Mark, I would think the first time you start and drive that it will feel so rewarding.

Y'know what would finish it off though, a flux capacitor. I'm sure they sell them at Maplins, failing that eBay

Hope you're keeping well mate anyway

Dave!!! I keep getting distracted by other cars, which I said I wouldn't modify, but have done!

It would be good to catch up in person.

[Excursion]

I spoke to Ian yesterday and he is going to collect the crank from the machinists over the Christmas holidays; the weights have been modified slightly. I'd like to get the engine finished next year as I'm missing the Fiesta at the moment. I'm fitting a new clutch to my F430 then I want to crack on with the Fiesta and start by wiring up the engine management.

Merry Christmas to all!

[Rhinopower]

Fitting your own clutch to the f430? Either something about the design makes it easy, or you're a fudgekin nutcase! Love you mark! Merry Christmas x

[Excursion]

Fitting your own clutch to the f430? Either something about the design makes it easy, or you're a fudgekin nutcase! Love you mark! Merry Christmas x

Haha. Most of the owners don't touch them - funny really! The clutch change is pretty straight-forward but if it wasn't, I'd still have a go The only non-standard bit is measuring clearance between the assembled clutch and release bearing flange, then shimming accordingly to set the preload.

You too bud

[Michael!]

there HAS to be an update...

[Smo]

Mark's probably rewiring a Eurofighter.

[FRSJON]

there a rather nice Italian car taking up all his time at the mo lol

[Excursion]

Sorry guys, nothing to report...yet

[Max M4X WW]

Delete Me

[Excursion]

Over the past week I've become very interested in the Fiesta one again. Before the hiatus I completed the bulk of the work from the rear of the car to the front bulkhead, leaving the engine bay and management loom to finish, and as of yesterday I have resumed work on completing it.

Ford EECV Engine Management
The original plan was to use the Ford EECV engine management loom from a 2002 Mk5 Fiesta Zetec - matching the car loom I'd used - to run the fans, A/C, and provide the VSS, ECT etc. signals to the instrument cluster; actual engine management duties would be provided by separate Pectel T6 ECU. The Ford ECU will actually output the necessary signals and run the ancillaries providing it is supplied with a CPS signal; technically it will be in limp mode but that doesn't really matter given its purpose as a slave to the Pectel 'standalone' unit.

The Pectel unit is very old now but still well regarded, and is the ECU of choice for a tuner in the Ford scene who has a fair bit of experience tuning high power Zetec Turbo's on their engine dyno, which happened to be built by Ian. For me the downside to the Pectel is that it's 15 years old, still fetches around £2.5k for a loom and unlocked ECU, and I end up with the semi-redundant Ford ECU.

The management I've always liked is the Focus RS Mk1 EECV; EECV is fairly powerful and mass air based whereas the Pectel is speed density. I'd originally given up on the RS EECV because none of the tuners seemed to have the hang of mapping it, but things have changed:



The Sabre rune is on a rolling road and not an engine dyn, but I've decided to go for it and keep an open mind about going back to Pectel and an engine dyno mapping session, if for whatever reason I'm not happy with the result. Going for an EECV allows me to keep a factory wiring loom, EOBD2 diagnostics, and emissions control systems such as evap, and dual lambda. With an ever greater focus on emissions it may help me to keep running the car further into the future.

EECV PATS Security
The PATS security/immobiliser system integrated into EECV ECUs need two programmed keys to enable an end user to reprogram another without diagnostic equipment; there's a learning process that can be followed from the drivers' seat. The problem for a project car is most used ECUs only come with one key - if at all! The answer was always a trip to a main dealer for a PATS memory erasure and reprogram for a new set of keys. Expensive and a little difficult to arrange for a partially complete project car.

Following a bit of research today I've obtained a freeware tool which can erase an EECV PATS ECU key memory and reprogram via the EOBD2 port for a new set of keys.




The transponder in Ford keys can only be programmed once, but I've found new replacements are readily available separately for around £5. Here's the tiny ID60 transponder unit - about 25mm long x 4mm thick:


Based on my new found knowledge I bought a used Focus RS ECU that didn't come with a matching key. £49.99

I will swap the transponders in my existing Fiesta lock set with new replacements and then reprogram the RS ECU for the new transponders (keys).

My Fiesta and EECV
The Mk3 Fiesta used the EECIV generation of engine management which is very old now, but I’ve installed a modified loom from a 2002 petrol Fiesta (Mk5) which did have EECV - so I’m part way there – but, there’s a catch; there are two types of EECV architecture: 60 pin and 104 pin.




The 104 pin has more input and outputs, and is used for turbo applications and TDi cars requiring DBW, and electronic fuel pump control etc.

The Focus RS of course uses the 104 pin management so I need to figure out how to best integrate that into my car. Thankfully there was one model in the 1999-2002 Fiesta range which did have 104 pin EECV, and that was the 1.8 Endura-DI turbo diesel. A few years ago I had the foresight to buy a complete loom from an Endura-DI car with A/C and EHPAS (very rare) – just in case...

I’m now working through wiring diagrams to determine my plan of attack. I've spent some time comparing pinouts in Excel and unfortunately the Endura-DI loom isn't remotely similar to the pin configuration of the Focus RS, and it’s complicated further by a different wiring colour scheme for Focus RS and Fiesta, so I’m now at the stage of planning the optimal approach for converting a Fiesta engine bay loom and fusebox for Focus RS EECV.

[Max M4X WW]

Blown away as usual!

Did the Mk5 Fiesta have electric power steering at some point then? Assuming that's what EHPAS stands for?

[Excursion]

Blown away as usual!

Did the Mk5 Fiesta have electric power steering at some point then? Assuming that's what EHPAS stands for?

Yes, it did. Quite ahead of its time really It was only fitted to the 1.8 Turbo Endura-DI engined cars from 1999-2002 that were specced with A/C and PAS - there wasn't room for a belt driven PAS pump and A/C compressor.

[Max M4X WW]

Nice, If I'd have known that I would probably have tried to bodge it onto mine

[Excursion]

Nice, If I'd have known that I would probably have tried to bodge it onto mine

Would have been good. It's pretty easy to do as well, and less hassle.

[FRSJON]

good to see the loves back for it

[cookie456_the2nd]

Just reading up on the electric PAS pump etc.

Do you know what signals it requires to run?

My mk3 is running a focus rs ecu, i was considering ditching the PAS, as require space around normal pas pump on my duratec, but this could be a feasible option if i can tuck the pump out of the way.

Edit:
Just checked on TIS, as far as i can work out, the EPAS pump has a ground, to ground of course, the live goes directly too the relay which is switched on by the engine ECU once the engine is running. So essentially as long as the relay can be switched on when the engine is running then it should be quite simple too implement.

[Excursion]

Just reading up on the electric PAS pump etc.

Do you know what signals it requires to run?

My mk3 is running a focus rs ecu, i was considering ditching the PAS, as require space around normal pas pump on my duratec, but this could be a feasible option if i can tuck the pump out of the way.

Edit:
Just checked on TIS, as far as i can work out, the EPAS pump has a ground, to ground of course, the live goes directly too the relay which is switched on by the engine ECU once the engine is running. So essentially as long as the relay can be switched on when the engine is running then it should be quite simple too implement.

Yep - that's it. I'm not sure the Fiesta Mk5 unit will suit wide tyres though, so depending on what you're running it may be better to use a more powerful unit.

[Excursion]

After my research into EECV which included a brief conversation with one of the development engineers on the Focus RS Mk1 project, I decided I just couldn't risk going to the effort of installing the system and being stuck with a 7k rev limit.

In view of the above, today I purcahsed:


T6 Motorsport - Ex Carlos Sainz WRC. 4 cyl, boost control, unlocked.

Engine update to follow before summer.

[Michael!]

Excited for the engine update.

Any pictures of the whole car how it is at present? Love this thread man, reminded me why inused to live on this forum.

[RS1800-Cookie]

After my research into EECV which included a brief conversation with one of the development engineers on the Focus RS Mk1 project, I decided I just couldn't risk going to the effort of installing the system and being stuck with a 7k rev limit.

In view of the above, today I purcahsed:


T6 Motorsport - Ex Carlos Sainz WRC. 4 cyl, boost control, unlocked.

Engine update to follow before summer.

whilst the pectel t6 is an awesome bit of kit its very dated now (10-15yrs old technology) from what i can gather theres better ECU's going for less new than cost of a pectel t6 2nd hand.

do you know how many inj and ign drivers this has and what features it supports?

I did alot of reserch on ECU's ... my engine builders b2b tested lots. results were supprising but ive gone for Specialist Components Delta 800 on his reccomendation. its used as production ecu on MONO kit cars

[Excursion]

whilst the pectel t6 is an awesome bit of kit its very dated now (10-15yrs old technology) from what i can gather theres better ECU's going for less new than cost of a pectel t6 2nd hand.

do you know how many inj and ign drivers this has and what features it supports?

I did alot of reserch on ECU's ... my engine builders b2b tested lots. results were supprising but ive gone for Specialist Components Delta 800 on his reccomendation. its used as production ecu on MONO kit cars

Agreed - it's old kit and OEM mainstream ECUs have been more powerful for a few years now, however arguably the most experienced ZT mapper has considerable experience with it and it's also what Ian recommended, so I have to balance the features of a given ECU with the experience & likely end result from the person creating the calibration.

The T6 was from a 4cyl Turbo WRC motor so has boost control - I will use air injectors for that. It should have closed loop too, but aside from those I'm not looking for any other features. I don't need CoP etc.

It cost me £245 which I think is OK. I know a lot of them sell for silly money given their age.

[RS rob]

well that was an interesting read,
only caught up a few years hahaha

brilliant as usual mark!!

[Excursion]

well that was an interesting read,
only caught up a few years hahaha

brilliant as usual mark!!

Rob! Hello mate

How's yours?

[moondustka]

Read a lot of the thread over on pistonheads.. The work you've put into this car is outstanding and each area a higher standard than most companies out there can produce.

Probably too late now, but from everything you've done (you seem to go for the best) I'm surprised at your choice of engine management. I would be going for either Syvecs or Life Racing, with drive by wire and adaptive knock control features. Perhaps you've heard of them, but your car would be worth a talk with Torque Developments in Thurrock. Sam there is extremely knowledgable to say the least.

Keep up the good work, anyhow!

[MK4 Rick]

Blown away as usual!

Did the Mk5 Fiesta have electric power steering at some point then? Assuming that's what EHPAS stands for?

Yes, it did. Quite ahead of its time really It was only fitted to the 1.8 Turbo Endura-DI engined cars from 1999-2002 that were specced with A/C and PAS - there wasn't room for a belt driven PAS pump and A/C compressor.

Hi mate anymore updates?These electric power steering pumps do i have to connect it up inline with the ecu?Or can i run a relay from it and connect to an ignition live

[Excursion]

Excited for the engine update.

Any pictures of the whole car how it is at present? Love this thread man, reminded me why inused to live on this forum.

Sorry, I missed this. Thanks!

Read a lot of the thread over on pistonheads.. The work you've put into this car is outstanding and each area a higher standard than most companies out there can produce.

Probably too late now, but from everything you've done (you seem to go for the best) I'm surprised at your choice of engine management. I would be going for either Syvecs or Life Racing, with drive by wire and adaptive knock control features. Perhaps you've heard of them, but your car would be worth a talk with Torque Developments in Thurrock. Sam there is extremely knowledgable to say the least.

Keep up the good work, anyhow!

Thanks. Pectel is a bit old now, though it's easier for me as the mapper has a lot of experience with it and ZTs. I may rethink later down the line.

Hi mate anymore updates?These electric power steering pumps do i have to connect it up inline with the ecu?Or can i run a relay from it and connect to an ignition live

The pump should be wired so that it can only run with the engine running. You don't need to wire it to an ECU.