Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Thanks Neal.

Here's the throttle cable adjusters that Titan leaves out of the kit. Only £2.50 for the pair, Only need one mind...

[Ken Welch]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Love reading about this. Great photos that show the build details and the high quality of workmanship.

Man after my own heart. Keep it coming.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Aligned the crank sensor. Used an m6 bolt through the crank pulley, and adam's loaned alignment tool. Thanks guys.

Fitted the s/s isolator pull switch. Found that the electrically operated extinguisher switch, on the front scuttle, had fallen to bits, so I'll order a new one.
Two jobs crossed off, another one added.

Fitted cable ties to the rubber boot on the new driveshaft, so stop it leaking grease.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Fitting the alignment tool to the sensor




Fit an M6 bolt through the crank pulley in to the engine block, to ensure that the crank it as TDC.

Push the alignment tool over the white tooth on the timing ring, and secure the sensor with the two M6 bolts.



Finally remove the alignment tool, and of course, the M6 bolt from the crank pulley.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Found a replacement for the Lifeline switch, a quarter of their price too.

https://uk.rs-online.com/web/search/searchBrowseAction.html?method=getProduct&R=0350282

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Switch has arrived from RS.


Started fitting the M-sport RH engine mount last night. I'll finish this evening, and i'l wire the new switch in too.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

w00t! - the RS switch is identical to the one supplied by Lifeline 8-)

[exboyracer]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

I suppose it's logical, it would have cost Lifeline too much to have a bespoke switch made.

Fancy charging four times as much for it though, cheeky buggers!

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Fitted the M-Sport engine mount last night. Not the easiest of jobs.

Once the standard ford mount is removed, the three excessively long bolts are removed from the timing chain cover. These aren't used on the Fiesta engine, for anything other than filling the holes from what I can gather.

The M-Sport arm is then held in place by 3 x socket head bolts, that replace the three removed (above) and two huge socket head bolts are used to secure the arm from above.

Now the tricky bit. The rubber insulator needs to be pushed out of the steel housing, and the nylone one inserted. But before you do that, you need to drill two holes in the metal housing, so the nylon insulator can be bolted in place to stop it from moving. Then you have to press the insulator in to the housing, and pray that the holes you drilled (above) line up with the holes in the insulator. My did! Phew.

Now for the really fun part. The insulator and metal housing, need to be fitted over the arm. I used plenty of car shampoo to lubricate the arm, and used a length of wood to prise the insulator over the arm, using the fiesta chassis to brace against.

Problem in the future will be how the hell do I remove the insulator to get the engine out? I normally lift the shell over the engine, but from now on I'll have to lift the engine out of the shell (carefully). But that will be easier with the Duratec as it no longer uses the same Fiesta Cross member that the Zetec employed so it will at least, lift out from above 8-)





I also ground down the old engine mount bracket on the inner wing prior to fitting the insulator/bracket, so thats another job crossed off. 8-)

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Booked in at SFS Luton on Friday morning for the hose fitting. If its all connected up on Friday, I can start the engine over the weekend.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

The engine mount is finished, and the XR2 is now back on her wheels again.

Started drilling holes in the carbon bonnet last night, to fit the 4 x mounting pins. Certainly not a job for the faint hearted...

[dobuy]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Never have so many waited with bated breath for the start up of a humble XR2

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

8-)

Bought a throttle cable (bike brake cable) from Halfrauds today, S/S so it shouldn't stick.

And the really good news today is that my neighbour from hell put his house on the market this morning, so I'm already planning the street party. All welcome.

[alladdin]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Never have so many waited with bated breath for the start up of a humble XR2

[exboyracer]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

What they said - this is too much of a tease!

8-)
And the really good news today is that my neighbour from hell put his house on the market this morning, so I'm already planning the street party. All welcome.

Awesome news! Hope the next lot are better neighbours!