Not so much a rebuild as an engine swap

[chris_cussen]

Re: Not so much a rebuild as an engine swap

The previous engine was DOHC carb version. I have a low pressure pump at the back and have put a HP pump at the front. HP pump to fuel rail will be new, everthing else will be low pressure, current hoses look ok, but I'm replacing fuel return to copper at the front as well. The idea of petrol spraying in the engine bay bscares me, I lost my rally escort to fuel leak.

[philcoyle]

Re: Not so much a rebuild as an engine swap

Have you got some kind of swirl tank fitted before the High Pressure pump, Low pressure feeding H.P. do the maths, you need a reserve in there somewhere.
I cheated and used a Ford Sierra fuel filter just before the injector rail. They hold nearly a litre of fuel at 45 p.s.i, so when the pedal goes down there is no shortage of fuel. Bonus, no costly custom made swirl tanks and still goes like a bat out of hell. Replaced all my fuel lines with high pressure plastic line suitable for 75 p.s.i and quite cheap. I only found out later that the pipes came in different colours and I could have used a different colour for feed and return, oh well maybe next time.
Spraying fuel leaks onto a hot engine tends to focus the mind!

[chris_cussen]

Re: Not so much a rebuild as an engine swap

Acoording to Mr. Haynes the fuel rail acts as a resovoir. The LP pump is a competition item and has a high flow rate. Time will tell. What engine do you have?

[philcoyle]

Re: Not so much a rebuild as an engine swap

Just a bog standard 2litre OHC pinto EFi with the 205 block, side exit homemade exhaust, type 9 box, LSD rear axle, and a grin factor of 10, but I would like to turn it up to 11!
16inch wire wheels, my design of coilover wishbone front suspension, Cortina uprights with discs, and 8 inch drums on the back.
You still need a fuel filter in there somewhere, so for a couple of pounds why not get the biggest capacity that you can.

[chris_cussen]

Re: Not so much a rebuild as an engine swap

I've two filters, one between tank and LP pump, and the other at the front just before the HP pump. You are right about the grin factor. Mine is standard Sierra with MT 75 gearbox, some polybushes in the suspension.

[chris_cussen]

Re: Not so much a rebuild as an engine swap

Well after ages faffing around, and failing to get the engine to run using a megasquirt ECU I've given up and bought a complete Zetec engine/ECU/Loom package from Omex. Installation should start in a week or so, so if anyone wants a Sierra DOHC 8v injection engine for free contact me before it goes to the scar yard.

[milliemarlin]

Re: Not so much a rebuild as an engine swap

Much to my surprise my old pinto engine with a cracked cylinder block went for £50 on eBay on a collection only listing. It’s got to be worth a punt. If only to save you the trip to the scrappy.
Paul

[greyV8pete]

Re: Not so much a rebuild as an engine swap

Well after ages faffing around, and failing to get the engine to run using a megasquirt ECU I've given up and bought a complete Zetec engine/ECU/Loom package from Omex. Installation should start in a week or so, so if anyone wants a Sierra DOHC 8v injection engine for free contact me before it goes to the scar yard.

Hi Chris. Have sent you a pm. Peter.

[chris_cussen]

Re: Not so much a rebuild as an engine swap

Well the engine is in
IMG_0504.JPG

Excellent work by Dean at Gillam's Car Spares, Wincanton in fabricating new brackets.
Problems so far
1. The clutch. Dean quickly worked out that the clutch would not operate as there was not way that the thrust bearing would make contact with the pressure plate. Since the object of the exercise was to fabricate the barckets we continued. I am thinking of using the old DOHC flywheel and pressure plate, since it seems to be of the correct dimensions. However the flywheel is huge, so the down side wil be that it will increase the inertia of the engine under acceleration. Still with 150 bhp on tap I don't think it will be a slouch.
2.The exhaust manifold (Ashley from Burton power) had a bend that made it come up into contact with the passanger floor. Dean heated the bottom bend with oxy-acetaline and I lent on a 6 foot scaffold pole to reduce the bend
3. The water rail (which replaces the thermostat housing on a Zetec) was so close to the bulkehad the ECU and instrument temp sensors would not fit. I'll try to get Omex to plug the holes and tap a couple more in the side of water rail.
So next weekend it is engine out and try the DOHC flywheel

[stevejgreen]

Re: Not so much a rebuild as an engine swap

Looking nice, but did you read up in Chris Dow's installation in a Roadster or consult zetec Inside.

[chris_cussen]

Re: Not so much a rebuild as an engine swap

I've read so much about doing a Zetec RWD conversion that my head spins. So I have decided that I would just press on and address problems as they occur.

[stevejgreen]

Re: Not so much a rebuild as an engine swap

I've read so much about doing a Zetec RWD conversion that my head spins. So I have decided that I would just press on and address problems as they occur.

Like.
Probably the best way provided you share!

[angusgrooby]

Re: Not so much a rebuild as an engine swap

You really will not look back once you have got the Zetec installed. I got most of my info for my Zetec installation from 'Paul's Zetec' type into Google and you will find his page you can use a 1.8 Zetec fly wheel which is lighter but not sure of the top of my head which clutch plate and thrust bearing you use. I used the 2.0 fly wheel and clutch just because the clutch plate looked new I also fitted a longer stud where the clutch fork pivets from you can buy them from kit spares I belive it changes the bite point on the clutch so it's not all at the top of the clutch travel.
Keep at it the engine looks Great. Angus

http://toyne.org.uk/zetec.html

[dcunn]

Re: Not so much a rebuild as an engine swap

Gold Star for persistence
Rgds DC

[chris_cussen]

Re: Not so much a rebuild as an engine swap

DOHC flywheel looks like a bust. The Zetec flywheel seems to have the crank sensor on its rear face. But the clucth cover is MUCH deeper so that may well be the solution.