fiestaturbo.com

[3lward]

I ENVY YOU!!!

look sweet though, top job!
but ive never seen it around, quite odd as this would grab my attention
as ive said, top job!

[knuckles]

just re read your whole thread.

your car has come along way fella - top job fella

[Dave G fsi]

Nice one mate, would love to get all new bits on my car like that!

[RS rob]

thanks for the comments guys

hopefully the updates will be coming thick and fast soon

[RS rob]

right its time to finish the car off

PLANS
- Restore the underneath of the car to a better than factory finish
- Its new engine time



about two years ago i bought an engine from a young lad that had a good engine from a guy called paul johnson
he's famous for a top speed run of 179.9mph (not with this engine)
it was the first zetec turbo that ian howell (fiesta frenzy/area six) made for a customer

2.1 16v zetec turbo
fiesta turbo OFAB managment with loom (including custom Ahmed Bayjoo map)
Ahmed bayjoo Injectors
Ported and Polished IH spec cylinder head
IH spec custom camshafts
forged pistons
Rover M16 Inlet manifold (rare) (not the inferior T16 manifold) which has been extended
Escort RST T3 Exhaust manifold

picture below, as seen in pauls engine bay
since then it was sold to someone else who did'nt end up using it
but now its my turn



so basically i've been in contact with ian howell,
discussed options and prices,
arranged for him to inspect/assess my engine then we will go from there.
we'll be aiming for a genuine 300bhp

more updates on sunday

[jonboisescort]

im liking the sound of that

[Dave G fsi]

Sounds brilliant mate

[RS rob]

as the engine is going to have a full revamp
ian / area six gave me a list of things to get
so i can take them when i drop the engine in for inspection and to discuss a plan of action

also i've bought bits which will help the engine to look new

all i can say i'm very thankfull for employee discount
some pics


sump bolts,
stem seals (inlet red - exhaust green)
flywheel dowels x3
focus rs spark plugs x4
zetec headbolts x10
flywheel bolts x6




sump gasket
camshaft seals
rocker cover gasket
oil pump seal and gasket




inlet manifold gasket
and then two head gaskets
one being a focus rs headgasket as i read this would be needed about a year ago
only to learn once speaking to area six its no good for my engine




water pump and gasket
water pump pulley
oil pressure switch
cps sensor




middle and bottom parts of the timing belt cover, as i have a clear top section




ford timing belt kit

[RS rob]

heres some parts i have ready for the new engine aswell

my spare cam cover sprayed the same colour as the car, with the letters polished then laquer'd over



fiesta turbo ofab ecu



wiring loom, looks scary



S2 escort turbo T3 manifold



rover turbo M16 inlet manfold,
adapted to fit the zetec by area six
fiesta turbo throttle body
fiesta turbo iscv
ahmed bayjoo spec injectors




area six spec cams



area six modified zetec head
head taped to fit S2 escort manifold
ported by area six

[RS rob]

heres some pics of the block, excuse the colours, not my choice at all

heres the block upside down on the engine stand (front breather blocked off)



standard zetec rods with arp bolts



the forged pistons



sump back on, you can see the oil return from the turbo on the sump



the back of the block, showing the breather pipe relocated here also the oil feed for the turbo



heres the van packed for the trip up to area six
you can also see the flywheel on its own

[RS rob]

well the trip to see ian howell or AREA SIX as he might be known
went really well, stripped the engine further and discussed plans
confirmed if parts were what i was told they were, such as cams being his spec etc



The overall plan is to freshen the engine up to a very standard
heres some of the things being done to the engine

- new valve guides as some of the originals had wear meaning the valve had play in the head
- new tappets , again signs of wear
- clean the valves up
- rehone the bores, possibly a rebore if needed depending on what ian's machine shop say
- crank is being polished
- all new bearings for the bottom end
- head having a fresh skim
- block is also having a fresh skim
- acid dipping the block
- adding an oil drain to the sump
- putting the whole engine back together with all new seals, gaskets, water pump etc
- also timing it up


decided to build the bottom end to a good spec incase i want more power in the future
so i'm having new forged pistons and steel rods with arp bolts (ian's spec of course)
so awaiting what happens with the bores first before the pistons and rods can be oredered

discovered the head has been machined for cossie plugs which is a good thing as they have a much wider range of spark plugs for the cossie lump, which means we can choose a better suited plug which runs at a certain temperatures which is suited to certain boost/power.

ian also had a look at my loom which i was dreading as it looked a nightmare, much to my suprise he disconnected the bits i did'nt need and helped me lable all the connectors

the loom went from this



to this, much happier
the parts with the green and yellow tape are not needed as their either diagnostic ports
or parts from the fiesta turbo loom which basically just are not used
i plan to tidy the loom up later on, but before i cut anything i want to make sure the engine runs first



also my car spit arrived in work, which will allow me to have my car on its side
making it easier to prep the underneath

[RS rob]

right so my plans are to have the fiesta bay stripped and painted
also got a few other plans aswell such as relocating the battery to the boot to make more room in the engine bay

so the old engine
originally a 1.8 16v 105 ps engine
rs1800 130ps spec throttle body, cams, ecu, maf sensor
only thing i was missing from the rs1800 was the 'HO' inlet manifold (high output - stamped on the back)
but still made 129bhp the last time it was on the rollers, i think it could of been more with the proper inlet

heres a pic




so the stripping began




beefy cossie wheels




inlet off, rear firewall out, engine loom out




rad out, thermo stat off, power steering rad out

[RS rob]

so the engine was ready to come out,
was very happy to see this come out, its been a good engine to me but
its time to move on to better things




always wanted to have the legendary photo in the engine bay




my old man was helping me at times, so had to get a picture with him haha



alot more room, but still lots to take out, but wanted to leave it so that i can still steer etc
as i have to move the car for the next stage





wiper linkage and motor out, heater fan unit out
taped up the hole so nothing falls inside the heater unit for now

[RS rob]

so i was up early to make room at work for the fiesta
was bloody cold as you can see my breathe

while i'm on the subject of the weather, i definutely did'nt pick the best week to take the engine out
as its been freezing everynight this week and even started snowing at one point.



new home for a while



later on i had the car picked up from the house



much better with more space, warmth, tools etc




cover over the top as its a dusty place





more parts including the following
-cossie spark plugs (ian told me which ones to get)
-thermostat housing bolts
-thermostat gasket
-crank pulley bolt (still waiting on a new crank pulley)
-waterpump pulley bolts
-timing belt cover bolts

[jonboisescort]

coming along nicely mate

look forward to another update

were do you work??

[rsonblackwheels]

awesome mate looks like good fun

very nice work space you got there too

very cool

[So_SiMpLe_]

Hi mate!

Good work keep up with it!

Tell a thing, the Vibratechnics mounts make the engine vibrate less?

What's the improvement by fitting those?

Thanks!

[Chopper69]

Just read the thread from start to finish...

Great job on the car looks lovely. Loving the new engine!

Cheer

Shaun

[knuckles]

love it

[MAD_Adamski]

rob i dont mean to pick here but if i were you i'd replace those arms for area 6 items or std frst ones,,, those ZOO item ARE DANGEROUS! so many peoples have broke and caused accidents i didnt think there were any left these das as the guy went under!

Ad

[Max M4X WW]

Looking great

I wonder if Ian could do something similar to my loom, As I'm not too happy with mine either and its OFAB like yours!

[jonyb4]

amasin work mate and all them fresh new genuine parts as usual, must be such a good omen working at a ford parts dept

nice to see a south wales guy with such a serious ford theyre getting rare i tell you

[RS rob]

coming along nicely mate

look forward to another update

were do you work??

cheers mate
fords bodyshop/parts

[RS rob]

rob i dont mean to pick here but if i were you i'd replace those arms for area 6 items or std frst ones,,, those ZOO item ARE DANGEROUS! so many peoples have broke and caused accidents i didnt think there were any left these das as the guy went under!

Ad

already asked ian about his lower arms, thanks for the advice mate
never heard or read should i say about these arms being dangerous though

[RS rob]

Hi mate!

Good work keep up with it!

Tell a thing, the Vibratechnics mounts make the engine vibrate less?

What's the improvement by fitting those?

Thanks!

they stop the movement of the engine quite alot,
but things will vibrate inside the car as they are quite hard

makes the engine feel more responsive from pulling off aswell

[RS rob]

right i've got quite alot of parts ready for this new engine
aswell as the engine itself,

so let the pics begin

Cossie group A airfilter ( bulb was the only thing i could find, to help show the size)




brand new ford rear engine mount




series two escort turbo lower boost pipe (samco)
new fords loom for between the alternator/starter/battery




clear zetec top timing belt cover to go with the other new timing belt covers
(to show my vernier pulleys)




gauges, oil temp, oil pressure, water temp, boost, air/fuel ratio and volts




newly refurbed starter motor




fiesta turbo GRS intercooler
planning to have this pressure checked and re-polished

[RS rob]

grs alloy rad with kenlowe slim fans




when i bought the engine i had a few extra bits aswell, silicone hose, metal pipework etc
(custom pipework from the throttlebody to the intercooler is at the bottom middle)




13 row mocal oil cooler





front strut brace with bracket holding the edis module and map sensor




rear strut brace with bracket holding a battery kill switch as i plan to move the battery to the boot




close up of the kill switch




false floor with ford battery tray to hold the battery in the boot securely

[RS rob]

sealed optima redtop battery for the boot and the ford battery clamp to hold it on the battery tray




distribution block on a bracket for the engine bay, basically needed to relocate the battery




some rare brand new original ford headlamp protectors
not sure wether to use these or not

[FiestaBen]

I like this car a lot, lots of hard work and the colour is stunning!

[jonyb4]

wow big purchase today then, alot of nice parts too

front strut brace with bracket holding the edis module and map sensor

coudl you tell me where you got this from or sorry if imwrong but it looks home made, where you got the metal from to make it? really interested in this

haha i hope that kill switch is insulated, that brace will be in contact with the shell

[RS rob]

wow big purchase today then, alot of nice parts too

front strut brace with bracket holding the edis module and map sensor

coudl you tell me where you got this from or sorry if imwrong but it looks home made, where you got the metal from to make it? really interested in this

haha i hope that kill switch is insulated, that brace will be in contact with the shell

i've had most of the things in storage lol

the pics did'nt do the strut braces any justice because it was dark +camera flash etc
made by a company called fusion fabrication!

[jonyb4]

oh i see lol sorry, seems you need them to be that small to fit behind that plenum?

can i ask you something, how much was that engine mount new?

cheers jon

[Max M4X WW]

That engine mount doesnt look anything like the one on my engine

[MAD_Adamski]

rob i dont mean to pick here but if i were you i'd replace those arms for area 6 items or std frst ones,,, those ZOO item ARE DANGEROUS! so many peoples have broke and caused accidents i didnt think there were any left these das as the guy went under!

Ad

already asked ian about his lower arms, thanks for the advice mate
never heard or read should i say about these arms being dangerous though

a lad off here a couple of yrs back had some same as yours and they snapped at 40mph if i remember correctly! Also the beam they did martin hatland snapped when he was on the gumball and nearly killed them! to be honest i'd cut your losses and get rid seriously no me being a 'conquering device', your life is in danger using them...

[rsonblackwheels]

blimey didn't know that

like all the new parts, look gr8