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Upps! there is some work....


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#21 DjFox

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Posted 23 March 2009 - 10:33 PM

That was so long to wait, and I was still bored ... so I decided to have more fans (to my club lol)... problem: the twin fans came from a late mk1 and wiring was different...ok I splited wires and ajusted the new to be compliant on mine :)

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MK1 GLX 1.8 16V Cayman Blue 93 with RS kit
Specs : All Ghia specs, Trip computer, AWS, Cruise control, Leather (BI-COLOR interior), Automatic Temperature Control, Adaptive Damping System, auto dimming mirror || GPS becker online pro, ALES module, Invisible Park Assist, Valeo automatic lights || Headlight leveling motors & CCFL & HID(6000k) || 21mm BAT ARB
Parts of élance pack : Floor mats, leather cd storage, leather ford user manual cover, rear wood door handles
2.0L specs : TB, ECU, cams, Intermediate, twin REMUS exhaust, cylinder oil jets, Low oil level sensor
Last mod => Valeo Automatic lights kit
Next mod => Power folding mirrors
Please keep MK1 & MK2 alive... so sad to see less and less on the road !

#22 DjFox

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Posted 23 March 2009 - 10:39 PM

Last mod fitted (this afternoon) : cylinder oil jets
As every Zetec-E have holes for them (except 2.0 L which have jets fitted from factory) I purchased jets and replaced the caps. it's really plug and play lol... May I say the mondeo is a Lego lol ?

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MK1 GLX 1.8 16V Cayman Blue 93 with RS kit
Specs : All Ghia specs, Trip computer, AWS, Cruise control, Leather (BI-COLOR interior), Automatic Temperature Control, Adaptive Damping System, auto dimming mirror || GPS becker online pro, ALES module, Invisible Park Assist, Valeo automatic lights || Headlight leveling motors & CCFL & HID(6000k) || 21mm BAT ARB
Parts of élance pack : Floor mats, leather cd storage, leather ford user manual cover, rear wood door handles
2.0L specs : TB, ECU, cams, Intermediate, twin REMUS exhaust, cylinder oil jets, Low oil level sensor
Last mod => Valeo Automatic lights kit
Next mod => Power folding mirrors
Please keep MK1 & MK2 alive... so sad to see less and less on the road !

#23 DjFox

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Posted 23 March 2009 - 10:57 PM

nice work!

looks like you have done some porting / smoothing on the cylinder head?

remember you will need a 2.0 ecu or remap, to get full use of the 2.0 TB and cams.

always best to fit a new clutch and release bearing while the engine is apart, in case you werent planning on it.

and its worth getting the flywheel machined down, its made mine pick up alot better.


Thanks a lot percy! we are working a lot to make the car back on the road soon :)

Yeah we tried to do some porting, but it's more a slightly smoothing, as it's hard to reach some corners in the head... we tried our best...but i doubt that's enough to get some HP or torque...

Well about ECUs... I have mine and a 2.0L Ecu and all I can say with the engine (when it's was used) i had noticed that :

- 1.8L ECU :
+ More torque at low revs
- More consumption (less mpg)
- Less power at high revs

- 2.0 L ECU :
+ More power at high revs
+ More MPG
- Less torque at low revs

I think the best would be a XR3i (1.8 130Hp) ECU...but I don't know if it would work, and they are quite rare(or expensive) to find.

Thanks for the advice, and don't worry it was planned, I've a brand new clutch & release bearing. The old one was very used...though it wasn't spinning.

What do you mean by 'flywheel machined down' ? Makes it lighter by making some holes in it ?
I know that 1.8L ones are smaller and lighter from 2.0L (220mm instead of 240mm) but I don't where, and how making it possible...
MK1 GLX 1.8 16V Cayman Blue 93 with RS kit
Specs : All Ghia specs, Trip computer, AWS, Cruise control, Leather (BI-COLOR interior), Automatic Temperature Control, Adaptive Damping System, auto dimming mirror || GPS becker online pro, ALES module, Invisible Park Assist, Valeo automatic lights || Headlight leveling motors & CCFL & HID(6000k) || 21mm BAT ARB
Parts of élance pack : Floor mats, leather cd storage, leather ford user manual cover, rear wood door handles
2.0L specs : TB, ECU, cams, Intermediate, twin REMUS exhaust, cylinder oil jets, Low oil level sensor
Last mod => Valeo Automatic lights kit
Next mod => Power folding mirrors
Please keep MK1 & MK2 alive... so sad to see less and less on the road !

#24 percybigun

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Posted 23 March 2009 - 11:08 PM

to get your flywheel machined, they stick it on a machine and skim a few millimetres off it.

the 2.0 ecu is programmed correctly for the overlap and duration of the 2.0 cams, the timing, and the extra air flow of the 2.0 TB. driving it on the 1.8 ecu it will run a bit lean.
Mk1 2.0 Ghia - Supercharged NOS etc
.________________________.
|............................................|
|.......Mk1 2.0 Zetec Turbo...... ||'|";,___.
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#25 neretva

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Posted 24 March 2009 - 08:26 AM

Oh mate, my Mondeo has an important oil leak too... I think our cars have worked a lot, but I'll never leave it, my Mondeo will always be my favourite car and I'll fix it as you have done!

Cheers!!!! :L


#26 rxt_ian

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Posted 24 March 2009 - 09:46 AM

So the headlight leveling motors can just be clipped in to std headlights?.... If so i think i know my next mod... :D
Monty the 94 Mk1 [color:red][/color] Red [color:black][/color](Not pink anymore :banana: ) GLX 1.8 hatchback with 150K+ miles

#27 DjFox

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Posted 26 March 2009 - 08:12 PM

So the headlight leveling motors can just be clipped in to std headlights?.... If so i think i know my next mod... :D


You need to replace the white plastic bit by the headlight leveling motor, then add the headlight inner wiring + the 6th pin (control) and finally add the selector in the dashboard.
On mine, wiring (from cabin to headlight) was already existing.
MK1 GLX 1.8 16V Cayman Blue 93 with RS kit
Specs : All Ghia specs, Trip computer, AWS, Cruise control, Leather (BI-COLOR interior), Automatic Temperature Control, Adaptive Damping System, auto dimming mirror || GPS becker online pro, ALES module, Invisible Park Assist, Valeo automatic lights || Headlight leveling motors & CCFL & HID(6000k) || 21mm BAT ARB
Parts of élance pack : Floor mats, leather cd storage, leather ford user manual cover, rear wood door handles
2.0L specs : TB, ECU, cams, Intermediate, twin REMUS exhaust, cylinder oil jets, Low oil level sensor
Last mod => Valeo Automatic lights kit
Next mod => Power folding mirrors
Please keep MK1 & MK2 alive... so sad to see less and less on the road !

#28 DjFox

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Posted 26 March 2009 - 08:23 PM

Mates, I need your help ! engine is back to its place but it doesn't run well :(
It seems that explosions happen in intake(mostly) or exhaust manifold...
The intake doesn't suck any air...(btw I haven't any brake power)
The car stall if I don't depress accelerator...

Tomorow we'll look if crankshaft/cam sensors are good... but if you have any other idea, I'll be glad you tell me. (That I could add to my check list)...hope tomorrow we'll find...

2 videos of the engine 'running' (you can hear explosions)

- Video 1
- Video 2
MK1 GLX 1.8 16V Cayman Blue 93 with RS kit
Specs : All Ghia specs, Trip computer, AWS, Cruise control, Leather (BI-COLOR interior), Automatic Temperature Control, Adaptive Damping System, auto dimming mirror || GPS becker online pro, ALES module, Invisible Park Assist, Valeo automatic lights || Headlight leveling motors & CCFL & HID(6000k) || 21mm BAT ARB
Parts of élance pack : Floor mats, leather cd storage, leather ford user manual cover, rear wood door handles
2.0L specs : TB, ECU, cams, Intermediate, twin REMUS exhaust, cylinder oil jets, Low oil level sensor
Last mod => Valeo Automatic lights kit
Next mod => Power folding mirrors
Please keep MK1 & MK2 alive... so sad to see less and less on the road !

#29 percybigun

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Posted 26 March 2009 - 08:53 PM

the wiring loom to the inlet manifold on mk1 zetecs is known to break up and cause starting probs and misfires, when the wires have been disturbed after an engine transplant.

otherwise it sounds like you havent got the vacuum pipes connected up properly, or some of them have got cracks/leaks in them

#30 DjFox

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Posted 30 March 2009 - 11:55 AM

This the last pics I had forgetten to share with you.

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MK1 GLX 1.8 16V Cayman Blue 93 with RS kit
Specs : All Ghia specs, Trip computer, AWS, Cruise control, Leather (BI-COLOR interior), Automatic Temperature Control, Adaptive Damping System, auto dimming mirror || GPS becker online pro, ALES module, Invisible Park Assist, Valeo automatic lights || Headlight leveling motors & CCFL & HID(6000k) || 21mm BAT ARB
Parts of élance pack : Floor mats, leather cd storage, leather ford user manual cover, rear wood door handles
2.0L specs : TB, ECU, cams, Intermediate, twin REMUS exhaust, cylinder oil jets, Low oil level sensor
Last mod => Valeo Automatic lights kit
Next mod => Power folding mirrors
Please keep MK1 & MK2 alive... so sad to see less and less on the road !