Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Its my lucky day. The rod bolts have arrived

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Drained the sump last night, and only discovered that a) the sump plug was loose, and b) I only had 2litres of oil in the sump. The joys of not running a dipstick.

Most of the oil leaked at the rolling road session when we couldn't stop the remote filter housing from pissing oil everywhere, must have lost a litre until Troy stripped it down and cured the leak. And the remote housing and Capri filter accounts for more than a litre, so I'll make sure when I refill the engine I measure how much I put back, and make a short dipstick calibrated to the amount in the sump.

I'll be putting the engine on its side this afternoon, to remove the sump. Just seeing if I can scrounge some RTV from work, as I'm sure B&Q white sealant isn't going to cut the mustard.

I may even go for an equivalent photo of me holding the engine, like Matt took, but although the engine is pretty light, even I don't think I have Matt's strength. Unless I photoshop it of course.

[cossie matt]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Hi Gray

I've used a few and have found Loctite 5910 Premium Black Silicone from Halfords the best. Designed for exactly what you need it for, I'm pretty sure it's what Ford use judging by it's looks post use and characteristics. Comes in a toothpaste style tube, about £7

HTH

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

I used Blue Hylomar in the end Matt Should be more than adequate, but thanks for the tip.

Pics from changing the flywheel to changing the rod bolts


Removing the original ST clutch and flywheel from a couple of weeks ago.





This is where the larger Mondeo sized Titan flywheel hits the gearbox bellhousing. It was already ground away, and I just had to take another 1mm slither off. I believe that just the Focus and Fiesta use the smaller diameter flywheel.


Changing the conrod bolts next. They require torquing up to 45ft-lbs.



The Fiesta ST sump is already baffled for fast road use.



Using blue hylomar to re-seal the sump


Refitting the sump (17 bolts hold it on)




Fitting the new AP paddle clutch and AP cover to the Titan flywheel





The Quaife gearbox back on the engine


My gearbox steady bar bracket that I made from adapting a standard bracket.



Lifting the body to allow the engine and box to be slid back in underneath from the driver side.



I'm concerned about the depth of the new clutch cover. The clutch release bearing is pressing against the clutch with the box bolted to the engine. Not enough to induce clutch slip, as the release bearing is spring loaded, almost as if it is supposed to rest against the clutch. I'll bleed the clutch first and make sure its working properly. Then if I'm happy, I'll start bolting everything back on.

I need to fit the neutral gear selector cable before I can refill the gearbox with 75/90 and then spend some time adjusting the length of the main gear selector so I can get it in to gear properly. Zorst, radiator, fuel, electrics, all 10 minute jobs so I should have it running by tomorrow evening.

Fingers crossed the new suspension clears the end of the box. Mr Hammer is waiting in the wings if it should still interfere.

[exboyracer]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Clutch works, feedback through pedal it feels good.
Suspension braces fitted, they clear the gearbox and sump this time. Gear linkage connected.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Suspension fits.
Radiator plumbed in.
New throttle cable outer fitted.
Osf hub and axle bar fitted.
Engine bay wiring loom fitted.
Fuel and.oil lines attached.

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Busy yesterday. Fitting the new Kustomengineering suspension, I notice that Neil from CF had also fitted them to his s/c mk1, as the June copy of CF Magazine has an article on how to install the kit.

Seeing as this latest setup from Karl is different to my last one, I used the article as a guide.

First problem, is that my kit came only with two 'rod end spacers' to fit on the Tie Bar bracket (page 93, picture 9), so the kit as far as I know, is only supposed to use one of the collars on each tie bar, not both on the one tie-bar bracket.

So fit a single collar between the brace and the red alloy heim, and not on top of the heim. That's how I've done mine and its fine. The thread depth in the tie bar bracket is deep enough for the M19 bolt to clamp tightly against the spacer/heim/brace so this confirms what I think is right.



Second problem the brace on the passenger side was 1cm too short to reach the tie bar bracket. So I had to lengthen the brace by cutting it, inserting some steel tube of the correct diameter, and welding the tubes back together. This could be because my car is shorter on one side to the other, or when Karl put the complex kink in to the brace to clear my Sequential gearbox, it was shorter than he anticipated. Either way, not insurmountable, and its on the car.


The good news is that the suspension clears the gearbox by around 2mm, and I still need to push the engine and box backwards towards the front bulkhead which will give me additional clearance. Its always the same when re-installing an engine, in that it can creep forwards when its first bolted up.

So on to getting the Radiator plumbed in, fuel lines and oil lines attached, engine bay wiring loom re-connected, throttle linkage repaired (the outer slipped at NMH and it created about an inch of free pedal play before the throttle opened), osf hub and axle on. Made a new gearbox steady bar, as the one I made with heims at either end was too harsh. I've now adapted a tube so the bar has an insulator on one end, and a heim on the other.


Just the nsf hub and axle to replace, and I need to fit the rest of the zorst. The neutral gear cable needs replacing which I'll do this afternoon.

Add water, open the garage doors, and she should be good to go

[exboyracer]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

All done. Loaded up on the trailer, and just need to book myself in at NHM for a suspension setup, and a couple of hours on the dyno to see how much more we can squeeze out of the standard engine. Now the rod bolts have been changed, I'm less concerned about caning it. And since I cured the overheating problem, we can keep running without having to let it cool down between sessions.



Time to send off my championship registration, get some tyres ordered, and send off a few cheques for events.

[Dan]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

great to see it back as a whole car

hope all goes well on the rolling road and i look forward to your first event report (just dont forget the pics)

[Tristan]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

great to see it back as a whole car

hope all goes well on the rolling road and i look forward to your first event report (just dont forget the pics)

same here!

[exboyracer]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Thirded

[team_zi]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

Ran the engine, all sounds ok. Throttle response is much quicker with the race flywheel.
Bled the front brakes. Nearly done for classic ford show.

[alladdin]

Re: Grahamb's Mk1 Fiesta XR2 Duratec HE Hillclimber

i shall be over for a dribble at cf