[Nismo Mark]

Bit of an update......

Been busy fighting the rust. It has been pretty much just surface rust so just a case of wire brush on a drill and then getting busy with the Hammerite















The rad support was quite rusty so I was going to clean it up and paint it but saw a new one was only £7 from Ford (thanks to my discount (but only £11 retail) so it was a no brainer



Also got new wishbones, droplinks and trackrod ends to go on

Just got to finish painting the subframe (bloody weather) and it can start to go together

[PumaJay]

good work on it, nice to see it being brought back to life

This post has been edited by PumaJay: 15 September 2009 - 06:32 PM

[hot wheels]

Say thats a good idea somthing to do in the winter.

[Mogsmex]

update please

[Nismo Mark]

As you asked nicely

Right this week got a few bits back in, fitted the new rad support bar, wiper motor, pollen filter housing, ran the loom back round etc.







Then Saturday I built the subframe back up with new drop links and track rod ends.






I have more pics on my camera which i will post up tonight but basically on Sunday I :

Checked tappet clearances and adjusted
Fitted new timing belt and tensioner
Fitted cam cover and belt cover
Fitted exhaust manifold

I also fitted the new clutch which might be of interest to you as I am not sure if anyone has done this before. I have gone for a Fiesta ST one as not only is it bigger in size slightly but also has stronger fingers hence more clamping force. Having looked at it in depth at work with some colleages we cant see any reason for it not working

The box went on ok but whilst doing so (i hade the engine tipped on its nose to make it easier) I noticed a leak from the cup plug on the water pump

Took the pump off the old engine and it looked like new so swapped them over

Fitted the cat and then slide the whole lot under the car ready for fitting this weekend.

[FlashBastd]

Interesting about the Fiesta ST clutch, the general theory was that it should fit, but no-one had been successful in actually getting it to fit.

Did you have any problems getting it on?

[Nismo Mark]

Interesting about the Fiesta ST clutch, the general theory was that it should fit, but no-one had been successful in actually getting it to fit.

Did you have any problems getting it on?

Nope it went straight on as did the box. the fun will be the first time the clutch pedal is pressed

The fingers on the ST one do sit around 3mm more inboard so if the slave cylinder cannot cope with that I may need to take the box back off and fit some spacers behind it.

[FlashBastd]

Really interested in how you get on with this, did you have your flywheel skimmed or anything?

[Nismo Mark]

No, there really wasnt any real wear on it so just rubbed it over with a sanding block.

Just checked the engineering drawings of both the Puma and ST slave cylinders and they have the same range so all looks well

There will be much swearing if the box has to come back off

[PumaJay]

thats interesting, im running a focus 1.8 clutch which is slightly bigger than the puma one

[FlashBastd]

Me too, but I had major slippage the other day during a swift pull away from a layby on the A1, so thinking about swapping to something a bit sturdier.

[Nismo Mark]

thats interesting, im running a focus 1.8 clutch which is slightly bigger than the puma one

The Focus clutch is bigger but the fingers appear to be weaker so dont offer a very good clamping force hence some slippage when pessed hard

[Mogsmex]

the focus clutch although larger is actually rated at less NM then a standard Puma clutch so it's technically a downgrade

which would explain your slippage...............

[Nismo Mark]

Other pics as promised

Old water pump


New(er) pump


Engine and box ready to slide under




Fitted

[PumaJay]

fitted-ish

[Nismo Mark]

Just been out to buy some more goodies for it

Brings the total list of new bits to

Timing belt kit
Clutch
Release bearing/slave unit
Wishbones
Front droplinks
Track rod ends
Rad support bar
Rocker cover gasket
Driveshaft seals
Heater control valve
Sparkplugs
Plug leads
Pollen filter
Air filter
Oil filter
Aux Belt
PAS fluid
Brake fluid
Engine oil
Gearbox oil
Coolant


If it fails the MOT I will be most upset

This post has been edited by Nismo Mark: 23 September 2009 - 01:30 PM

[Nismo Mark]

Well its in







Decided instead of waiting till saturday and hiring a hoist I would drop the car down, attach the mounts and then jack the whole lot back up

The end is in sight (hopefully)

[Nismo Mark]

Well I piped the clutch in last night and bled it. The good news I can report is the pedal feels like its working as it should

Obviously there is no way of telling 100% until you try and drive it but so far I am happy

hopefully it should be as good as finished over the weekend

[Nismo Mark]

Over the weekend made quite a bit of progress Wishbones on, droplinks and Rod ends connected and driveshafts fitted. Also fitted the PAS hoses and pot and filled with fluid.







and then today fitted the wings and the coolant circuit with tank.





But then when changing the oil filter I sotted this



It actually looks like its coming from above the water pump so tomorrow I am going to take the alternator off to try and get a better look but it could mean the belt cover has to come off at least

[Nismo Mark]

Stripped it all back out and the water pump is fubar, coolant was leaking out the bleed hole in the top so the seal is knackered

Should have a new one to fit for the weekend