finally a new Fiesta RS Turbo owner :)

right everyone after the sale of the previous car fell through (less said the better) :wall:
i had a great bit of luck and dropped on this motor from a cracking guy from up cumbria :god:
its totally different spec wise to the white one i was going to get and i actually prefer that if im honest as its a lovely base to make a great car from and not ruin the oe looks/charm of it too much. :top:

its a 1990 car in red
totally standard engine wise apart from a receipt for some form of hybrid turbo
stainless system
lowered suspension
had a resto a few years ago and is in great shape nice and solid in all the usual areas.
also had an engine rebuild a few years ago

the car has not been on the road since 2014 but the current owner took the car for a pre mot on monday and it failed on the following

emissions too high
handbrake cable needs adjusting
spare wheel needs a tyre
one headlight not working
reverse light switch intermittent

and that was it so the plan is to give the car a real good full service including the following

oil and filter
ht leads and denso ik27 plugs
fuel filter
uprated frst fuel pump
coolant change
drive belt
cam belt and water pump kit
new set of wipers all round
new set of bulbs all round

the owner also informs me that the turbo will need a rebuild which is not a problem as it will go to my mate wilky for the said work and possibly a bit more of his magic work.

i also have my other mate who is a professional detailer booked in for the end of march to give the car a full paint correction detail and interior valet etc etc so the car will look spot on once done.

the plans are then to refit rebuilt turbo and then get the car an m.o.t. once this is done ill be calling msd for one of there set up sessions and if all well followed by there stage 3 conversion on the same day

looks wise with the car i dont really want to change anything apart from i think its crying out for the period 4" tailpipe on there D:

anyway enough babbling from me for now here are a few pics for you all

 

[T9 man]

That's a nice snug fit there Andy, just wondering, can you just paint the cut edges or do you have to treat it first with something?

 

[andy206]

That's a nice snug fit there Andy, just wondering, can you just paint the cut edges or do you have to treat it first with something?

hi mate yeah its a real snug one but certainly better than having to butcher the front bumper i cant stand seeing that.

well thats where the advantage of being a painter and decorator comes in, all the edged will be filed down neat/smooth then treated to 2 coats of metal zinc primer followed by a coat of red hammerite.

 

[obi_waynne]

Keep the updates coming. You're pretty much all set for summer now!

 

[andy206]

bit of an update last saturday the rad and intercooler was properly fitted and thermostat housing with low temp thermostat and new gasket was refitted along with uprated fan switch.

fan was tested to make sure it worked before refitting the bumper and i must say im very happy with the stealthy look of the intercooler only thing that is bugging me is the writing on the hose that can be seen.

we have also relocated the amal valve to the inner wing and im just waiting on a little silicone bung to arrive to blank off the hole on inlet.

All that iv gotta do now is refill with coolant and obviously run upto temp etc etc then ill be taking the car over to my mate karls one weekend so we can fit the new fuel pump and uprated loom amongst a few other jobs.

Then it should be just about time to get it mapped and also the escort turbo oil return mod done which should help massively with the crappy oil return set up as oe on the fiesta
__________________

 

[andy206]

Boostmonkeys ofam ecu has arrived. Got a final few jobs to do then it will be going to get mapped at around 18psi.


also just popped out to the garage to fit the silicone end cap onto the inlet from where i moved the amal hose from, so i thought id get a couple of quick pics of the finished set up of rad and intercooler.
over the moon with it nice and stealthy just what i wanted

 

[andy206]

Yesterday i managed finish early and decided to get outside and get the car running, so it was topped up with coolant and usual procedure, checked for any leaks etc and also glad to say the new fan loom/switch and thermostat is working perfectly (only on manual switch before).

quick video of it running on 1st start up.

i then pulled the car out slightly so i could give the garage a bit of a tidy and de clutter as much as possible, not the best pics but hey ho.




the plan is to take the car for a run up around the staffs moorlands (roaches) tomorrow and stop off for some lunch and a few drinks at a nice little country pub i know, looking forward to it and have the AA on speed dial just in case haha.

 

[T9 man]

 

[andy206]

well on sunday we finally got out for a bit in the car, only did around 10-12 miles as we had got other arrangements for the day.
The car drove faultlessy and got alot of attention when at the petrol station and also on the way home 2 guys in about there mid 40s gave me the thumbs up

Im going to take the car to have the geometry/tracking set up as its defo pulling to the left and id imagine never has been set up right.

We stopped off at a local country pub for a bite and a pint before heading back so i thought it was rude not to take a couple of pics.

 

[T9 man]

The car drove faultlessy and got alot of attention when at the petrol station and also on the way home 2 guys in about there mid 40s gave me the thumbs up

How cool is that Andy
You see, we are not the only ones who appreciate beautiful looking classics good sir

 

[andy206]

How cool is that Andy
You see, we are not the only ones who appreciate beautiful looking classics good sir

its not bad if i do say so myself must admit im starting to feel happy with how the car is coming together.

 

[andy206]

Today i finally got to take the car to get the mongoose 4" box fitted and get the magnex back box and silencer removed.
Now it looks and sounds like an rs turbo should imo. Proper period mod.
Vid to come later.

got a few pics of the little outing

first thing this morning in the drive whilst checking tyre pressures etc etc


the last pic of it with the magnex rear box on


1st pic of the new box in place


bit of a better shot of it in my drive before putting in the garage


safely tucked up until tomorrow morning


sorry there were no pics at the exhaust place etc as i just dropped it off then went to get some breakfast and go to view some family pics we had done last weekend.

 

[andy206]

had today off work other than to go quote a job so i can look after my son whilst the wife goes to be pampered ready for the wedding were off to tomorrow.

anyway decided to take advantage and pull the car out for a little maintenance wash and hoover out, also got the rear boot release working again

got a few pics sorry if the quality isnt upto much as im using an s5 atm due to my own phone not liking water lol

 

[andy206]

hi guys sorry for lack of updates but truth is theres not a great deal to do so.

below is a copied post from back in june and then an up to date one from today

hey everyone hope we have all been out enjoying the weather and managedd get the motors out for a boost.

i had the fiesta out yesterday morning 1st thing for a bit of a drive, really enjoyed it especially when i had a guy in a ferrari 360 coming in opposite direction flash his headlights and give me the thumbs up.

something thats been bugging me is we cannot get the car to stop smoking (defo oil related), turbo was new last feb, we have replaced a whole host of things and even did the stem seals last week to no avail.
next thing were going to do is the escort rs turbo oil drain mod as i hear its a common problem with the oe oil drain that it overfills the turbo etc.

if this doesnt cure it then im going send the turbo back for inspection.

(today)
well after what seems an absolute age i can finally update how things have been going with the car.

i sent the turbo back to wilky to be inspected and he confirmed what i already knew that the turbo was still in as new condition from when he built it for me. He did say just how much oil was in there though which was no surprise.

now heres why theres been no other updates, since receiving the turbo back iv not had any chance to get out there and inspect/refit etc.

last weekend me and karl3dr had an afternoon of checking over the breather system and everything seemed to work as it should no blockages etc.

next step is to refit the turbo and then carry out a compression/leak down test and go from there, just a note the engine runs sweet as a nut and were still to do the erst oil drain mod.

fingers crossed we get to the bottom of this asap so it can be sorted ready for alot more use next year

 

[T9 man]

Nice one Andy, and I wish you the very best of luck with the fault finding sir, you know, that Fiesta RS is my baby too

 

[andy206]

Nice one Andy, and I wish you the very best of luck with the fault finding sir, you know, that Fiesta RS is my baby too

thanks matey we are having a day on it on the 27th december, iv also bought an aem wideband kit and a boost gauge to install.

merry christmas to you all

 

[T9 man]

All the best to you and yours Andy

 

[andy206]

Well it looks like we might of got to the bottom of the reason for my car smoking like bob marley. Done a compression test today got 100psi on 1-3 and 110 on 4. Got the head etc whipped off for a closer inspection. First spot is looks like old head bolts were used at some point as a couple are stretched and looks like the bolt holes were not cleaned out so the ends were properly shitted up and certainly not torqued up correctly.

All pistons are now removed looks to be signs of wear on the crank bearings and some marks on the side walls of the pistons, bores look to be pretty smooth with very light honing marks showing.

head and bottom end will be going to a local engine place to be thoroughly investigated and then see whats going be needed to make it all spot on again.

 

[T9 man]

I do so hope that there is a happy ending to this latest hiccup Andy. While it’s stripped down, are you going to get any additional work done on the engine even if it gets a clean bill of health?

 

[TCJBOLDIE]

FWIW bin the factory head bolts and install ARP studs and a MLS gasket

Make sure that the valve guides are within spec and new stem seals installed.

Take a comp test when the rebuilt motor is installed and keep a record of the readings including the leakdown test.

The turbo drain should be a minimum of say 3/8ths internal diameter and as straight as possible with no bend more than 45 degrees as it is gravity drain back into the sump.

The only metal to metal contact is the rings to cylinder walls so DO NOT drive like Miss Daisy as the rings need gas pressure from behind them to seal correctly.

I would advise that you at least read motormans running in method. http://www.mototuneusa.com/break_in_secrets.htm

 

[andy206]

I do so hope that there is a happy ending to this latest hiccup Andy. While it’s stripped down, are you going to get any additional work done on the engine even if it gets a clean bill of health?

hi mate at least we now know whats been causing these problems for so long. The head will be getting a full refresh/cleaned/valve guides/valves checked relapped but no porting etc. Going to of course be fitting a whole new engine gasket set, new head bolts, arp rod bolts, new cam belt/water pump, new high pressure oil pump, crank will be polished and new mains/big ends and thrusts fitted, block will be re honed and possibly rebored if needed. Piston wise we will see what report comes back to if i need new ones or just new rings.
basically just an oe engine build as im not going for silly power i was considering it but 180-200bhp will be fine in a little fiesta and sure to put a smile on my face.

FWIW bin the factory head bolts and install ARP studs and a MLS gasket

Make sure that the valve guides are within spec and new stem seals installed.

Take a comp test when the rebuilt motor is installed and keep a record of the readings including the leakdown test.

The turbo drain should be a minimum of say 3/8ths internal diameter and as straight as possible with no bend more than 45 degrees as it is gravity drain back into the sump.

The only metal to metal contact is the rings to cylinder walls so DO NOT drive like Miss Daisy as the rings need gas pressure from behind them to seal correctly.

I would advise that you at least read motormans running in method. http://www.mototuneusa.com/break_in_secrets.htm

hi mate thanks for the reply
re head bolts victor reinz ones are more than adequate and 99% of cvh turbos run them these days, also payen head gasket is the one to go for as alot of them out there didnt have the double fire ring and were sold as turbo gaskets.

we installed new stem seals not even 10 miles ago so they will be absolutely fine and of course all the head will be refreshed at the engine shop that im taking it to.

comp test will certainly be done once rebuilt and running and im getting a compressor so we can carry out a leakdown test.

with regards to the oil drain this is finally going to give me chance to do the escort turbo drain mod which is a much better design than the oe fiesta one, we actually checked the feed etc the other day and all seemed ok.

i think iv had to bed in 4 rebuilt engines down the years (yes im that lucky) haha so iv got a fair idea about bedding/running things in etc and obviously changing the oil after about 500-600 miles or so.

lucky thing for me is my best mate who will be building the engine up with me is a top mechanic for ford and trust me hes very particular about how he does things

Really do appreciate your tips/advise

 

[TCJBOLDIE]

Don't forget to use a dedicated "running in oil" or a mineral oil and definatly no synthetic for a 1000 miles or so.
Good luck with the rebuild

 

[andy206]

Don't forget to use a dedicated "running in oil" or a mineral oil and definatly no synthetic for a 1000 miles or so.
Good luck with the rebuild

oh yeah of course mate iv got some sae30 up at my parents place still although i will need a tad more.
thanks alot fella be prepared for many updates over the next few months

 

[andy206]

on new years eve i had a spare hour or so i stripped all bits off the head ready to be taken to the engine shop for required work.






i also took a couple of quick pics of the pistons etc and will get much more as we go on




The bottom end is being dropped off at the engine shop on sat 20th jan to be inspected and then we shall go from there with whats required etc.

 

[andy206]

i had a spare hour this morning so decided go out to the car and remove the following ready so we can unbolt the block etc next week and get it out the car

radiator,intercooler,alternator,starter motor and any associated hoses/plugs etc

looking forward to removing the block next saturday now, i got a better look at the cylinders and they look really smooth so will defo need re honing at least.

 

[andy206]

today i got a job finished for midday so i got home and decided strip the remaining bits off the head and took it upto my local engine shop so he can strip and inspect and tell me whats going be needed.




i also thought id get a quick pic of how the car is looking in the garage atm, pretty bare and even more so after saturday when the bottom end is removed

 

[TCJBOLDIE]

Love your enthusiasm and lkeeping us up to date with everything but am concerned with the rusty? water on the of the block.

Hopefully the machine shop will acid dip the block to remove any gunk in the galleries before rebuilding the bottom end.

Am intrigued with the unusual cam and valve arrangement.

 

[andy206]

Love your enthusiasm and lkeeping us up to date with everything but am concerned with the rusty? water on the of the block.

Hopefully the machine shop will acid dip the block to remove any gunk in the galleries before rebuilding the bottom end.

Am intrigued with the unusual cam and valve arrangement.

no worries at all and im glad you enjoy reading them

oh yeah the head goes into the hot wash and is fully decarbonised etc etc so it will be like new, actually had an email from the engine shop earlier saying the head was all stripped and inspected, all 4 exhaust valve guides are shot so 4 new ones of them will be going in.

 

[dawuddustin]

Looks like a great car! Awesome

 

[andy206]

Looks like a great car! Awesome

thanks and a very rare sight now also

 

[andy206]

engine shop got back to me on the evening i had dropped the head off, all inspected and requires 4 new exhaust valve guides as they were absolutely shot. I got some new ones from burtons and dropped them off earlier

the head will be getting the following

Exhaust valve guides replaced
Recut valve seats
Reface valves
Reface head
Strip, decarbonise, grind in valves, hot wash, re-assemble & pressure test

that should sort that area out and the worn exhaust guides would of certainly contributed to the car smoking its head off.

 

[andy206]

today me and my mate karl removed the bottom end from the car ready to take to the engine shop next saturday

please note we cleaned one piston up to see if there was any info etc on it, as you can see quite alot of carbon build up.





we are really hopeful that it only needs re honing, new rings and new big ends

 

[andy206]

i stripped the inlet down today as im going to take it to the engine shop to go into the hot wash with the sump and cylinder head, im glad i decided to do this as the inlet is really filthy inside so wont do it any harm to be cleaned.




i have also discussed getting my flywheel lightened by them which ill be going ahead with

 

[TCJBOLDIE]

Tip 1 get the manifold port matched to the head and use a flap wheel to smooth out any casting dags as well in both the ports and manifold.

Tip 2 if you use a fuel cleaner on a regular basis then the mani ,ports and combustion chamber will stay cleaner

Tip 3 if you install a thermal manifold gasket you will get less heat transfer to the manifold so the incoming charge will be a little cooler resulting a little more power.

It would be a shame if you don't do the above while you have the motor in bits.

I have this and more done to my car.


http://www.autospeed.com/cms/article.html?&title=Cool-Stuff-Manifold-Insulators&A=110474

PS I would also get the injectors serviced and flow tested as well so everything is spot on for the best all round result.

 

[andy206]

Tip 1 get the manifold port matched to the head and use a flap wheel to smooth out any casting dags as well in both the ports and manifold.

Tip 2 if you use a fuel cleaner on a regular basis then the mani ,ports and combustion chamber will stay cleaner

Tip 3 if you install a thermal manifold gasket you will get less heat transfer to the manifold so the incoming charge will be a little cooler resulting a little more power.

It would be a shame if you don't do the above while you have the motor in bits.

I have this and more done to my car.


http://www.autospeed.com/cms/article.html?&title=Cool-Stuff-Manifold-Insulators&A=110474

PS I would also get the injectors serviced and flow tested as well so everything is spot on for the best all round result.

all duly noted mate thanks for that i will in fact be changing the injectors once run in to larger ones ready for remapping and they will be serviced for sure.

on another note there might be a slight delay in dropping bottom end off as im very busy this saturday quoting various jobs all over the city.

 

[andy206]

in keeping with talk about costs i today ordered a few more parts

complete head gasket set with oe spec payen gasket
victor reinz head bolts
complete bottom end gasket set
cam belt/tensioner and water pump
high pressure oil pump
ARP con rod bolts

i have also bought a full engine nuts/bolts/studs/washers etc set from retro bolts so we know we will have fresh stuff and nothing missing or incorrect.

 

[TCJBOLDIE]

What exactly is "a hi pressure oil pump" what was the max hot pressure with the old pump ?
You only need 10 psi per 1000 revs.
When you think about it the pressure readings are resistance to flow.

 

[andy206]

nice little update for you all

iv not long been back from the engine shop ill let the pics do the talking







absolutely over the moon with the work thats been done and will certainly be a far better head to start with.

also received the head and engine gasket sets



we are getting there bit by bit

 

[TCJBOLDIE]

Looking good so don't rush and do it right and you will be more than happy with the end result.

 

[obi_waynne]

Thanks for all the updates, been keenly watching this one buddy. Keep us posted with your progress.

 

[andy206]

Looking good so don't rush and do it right and you will be more than happy with the end result.

cheers mate theres certainly no chance of it being rushed, want to make sure its as good as possibly can be.

Thanks for all the updates, been keenly watching this one buddy. Keep us posted with your progress.

no problem hope your enjoying the plodding progress haha