Extra turbo

[Brigsy]

Updates - efi conversion in progress. Mock up stage

Last view of the old setup

Efi inlet, vw coilpack for wasted spark and dizzy blank fitted


Trigger wheel and crank sensor fitted - not welded as looking at 60-2 flywheel options


Made a start on routing wiring into the engine bay

Ended up whipping the dash off its clips to aid access

32mm hole drilled to suit - have a rubber loom bung to suit

Wiring in engine bay ready to route/drill more holes

 

[Brigsy]

Current flywheel situation. I have been looking at flywheel options to ditch the trigger wheel setup. The trigger wheels are known to move unless welded/dowelled - it would work ok but a proper flywheel would be miles better in my opinion. Ttv do a gtt flywheel with 60-2 trigger but £380 which is a bit steep for my budget. I read that a K7M flywheel would bolt up to a c series crank with correct trigger so sussed out a cheap K7M flywheel on ebay for £28 delivered off a 1.6 8v Megane/scenic ph1.




Test fit on c3j crank - bolts up ok 60-2 trigger

Clutch is 180mm and same size as stock c3j compared to 200mm gtt
Campus pressure plate bolts up

I have a couple of options with this flywheel - one is 7-1/4" race clutch and cover which would work fine (ap or tilton) downside is expensive. I reckon a machine shop could face and redrill to suit 200mm gtt clutch.

However they seems to be a 215mm option for K7M so i have a laguna 1.6 8v flywheel on order. If this works out i might be able to bolt a 172 clutch up. Will see what its like once it turns up.

 

[andybond]

Should be able to take some meat out of that flywheel as well for faster revving?

 

[Brigsy]

Shpuld be able to take some meat out of that flywheel as well for faster revving?

Im going to try stock weight this time round - possibly look at balancing with the rest of the rotating assembly. I hear stock flywheel weight may be better for turbo spool so only one way to find out

 

[TNT Andy]

Current flywheel situation. I have been looking at flywheel options to ditch the trigger wheel setup. The trigger wheels are known to move unless welded/dowelled - it would work ok but a proper flywheel would be miles better in my opinion. Ttv do a gtt flywheel with 60-2 trigger but £380 which is a bit steep for my budget. I read that a K7M flywheel would bolt up to a c series crank with correct trigger so sussed out a cheap K7M flywheel on ebay for £28 delivered off a 1.6 8v Megane/scenic ph1.

View attachment 91821
View attachment 91822

Test fit on c3j crank - bolts up ok 60-2 trigger
View attachment 91823
Clutch is 180mm and same size as stock c3j compared to 200mm gttView attachment 91824
Campus pressure plate bolts upView attachment 91825

I have a couple of options with this flywheel - one is 7-1/4" race clutch and cover which would work fine (ap or tilton) downside is expensive. I reckon a machine shop could face and redrill to suit 200mm gtt clutch.

However they seems to be a 215mm option for K7M so i have a laguna 1.6 8v flywheel on order. If this works out i might be able to bolt a 172 clutch up. Will see what its like once it turns up.

That's the one in mine Jonny - as per C.Miller back in the day

 

[Brigsy]

That's the one in mine Jonny - as per C.Miller back in the day

Thats the one. Have you used it instead of trigger wheel ??

Laguna 1.6 8v flywheel has arrived. Bolts straight onto the c series crank & same 60-2 trigger pattern. The flywheel has a 215mm clutch so need a 172 clutch to check fitment. Looks promising though

 

[Adey]

thats a winner of a find there then, the stock 172 clutch can take a bit of poke too, though not sure if it will take what you can chuck at it?

 

[Iain]

Very interesting!

 

[Brigsy]

Slow progress but engine bay wiring routed..should see a fire up in next few weeks.

 

[TNT Andy]

Looking great Brigsy - have you done anything else whilst converting to EFI?

 

[Adey]

mate your fleet is awesome, you know youll have to boost the kangoo soon yeah?

 

[Mark Davis]

Thats the one. Have you used it instead of trigger wheel ??

Laguna 1.6 8v flywheel has arrived. Bolts straight onto the c series crank & same 60-2 trigger pattern. The flywheel has a 215mm clutch so need a 172 clutch to check fitment. Looks promising though

View attachment 91869View attachment 91870
View attachment 91871View attachment 91872

I’ve got a 172 clutch, flywheel and cover you can have for free if you cover postage mate. Let me know and I’ll take some pics, came off the engine I recently bought.

 

[Brigsy]

Looking great Brigsy - have you done anything else whilst converting to EFI?

Cheers mate. Not done any other mods yet - im thinking fresh engine same spec - fuel system upgrades and lsd at the mo - a few new gauges etc.

mate your fleet is awesome, you know youll have to boost the kangoo soon yeah?

Ive been offered a forged R26 engine with rs250 head for the kangoo. Seriously considering it at the mo as can slip an ndo box in with lsd - full package will only be a little bit more than fitting a quaife to the jc5 lol

I’ve got a 172 clutch, flywheel and cover you can have for free if you cover postage mate. Let me know and I’ll take some pics, came off the engine I recently bought.

Cheers for the offer mate i need to change the clutch in the kangoo very soon so will have the old one here. The clutch release bearing is chirping like a mofo lol

 

[andybond]

Ive been offered a forged R26 engine with rs250 head for the kangoo. Seriously considering it at the mo as can slip an ndo box in with lsd - full package will only be a little bit more than fitting a quaife to the jc5 lol

All the best bits you mean?

I am smashing f5 on the other project thread expecting an update.

 

[TNT Andy]

Yes - remember you saying something about a massive crack some time ago and was thinking, hmmmmm - I think I would be replacing that at this point. And in answer to your question many moons ago - yes, I used that flywheel as my trigger wheel - no issues.

 

[Brigsy]

Update as its nearly xmas. Ptfe fuel hoses done, attempted fire up but battery shot & spark plug change needed. Should be on for a start before end of year.

 

[Brigsy]

Boxing day attempt at fire up.

Armed myself with new Ngk BCR8ES plugs, new Exide 063 battery & 20ltrs of Tesco's finest 99 octane. Loaded a good base map on, turned key & fired up first turn to a steady idle. Needs some fine tuning but nice to hear it run after all this time.

Vid below, select 480p as youtube is selecting very low qualiy for some reason.

 

[Adey]

cold start ability achieved + 5 cool points

bet thats given you a bit of a boost for getting it done. whats next in the pipeline?

 

[Brigsy]

Theres a few bits to sort out - Needs a bit of wiring finishing off on the ecu side & some fault finding to find out why it wont rev clean. Got another crank sensor on order & looking at fuel pump options at the moment as on what i recall to be a stock ph1 bosch pump currently. As soon as im happy that it will run & drive in a fashion ill pull the engine out & build the new one up, get it road legal as should not need much, if anything for mot.

Goal is back on the road for April/May in the new year, providing everything goes well should be doable.

 

[Brigsy]

A bit of fault finding today, found a loose connection on the earth wire for the crank sensor, fixed that and fitted a new genuine ford zetec sensor. I had a feeling it was ign related the other day, it revs great now although a little bit lean. Not messing about with map yet, will change fuel pump and revisit. Its drivable now though.

Altered transient throttle to use map prediction as per @DaveL485 's advice which made it rev cleaner also added a little bit of fuel across the range with the master trim. Just playing about cant really hurt the current engine much, needs to run right for the fresh engine though.

Wiring 90% done, just need to connect afr controller to ecu (need to find my 2.5mm jack lead as using the w/b output on my gauge) and wire up mac valve.

Ecu stealth mounted in fusebox cover

Stuck bonnet back on and give it a blast off with the lance, snowfoam and pressure rinse. Ran out of light so stopped at that, its come up clean for its first wash in ages.

A couple of vids

Startup, it fires up first time every time now got to love efi. Im used to this needing a shit load of cranking on carb to fire up.

Select 480p or higher as youtube is wank now and downgrades quality massively



Revs clean. A bit lean when on and off the throttle will revisit with new fuel pump. Map may need adjusting but will hang fire for now.



More to come in the next few weeks !