Tony,
You will have to let me know how you get on. I have just bought a
2000 Fiesta Turbo Diesel
with the Endura DI engine which I plan to put into my saloon. There
looks to be a lot of
stuff to try and jam in the engine bay of a saloon.
Russell
On 12/06/2010 22:15, TonyV wrote:
Well, after a bit of a struggle, I managed to get the insurance money
for my Mondeo (see Fun in the Snow thread from January). It only took
5 months, so yar boo sucks to 1st Central insurance, who were so
incompetent that I told them to cancel my claim and worked directly
from the other guy's insurance myself.
1st Central STILL haven't refunded my unused insurance premium,
despite the policy having been cancelled on 22nd March.
Having purchased a couple of Haynes manuals, I haven't yet managed to
get one which relates to this exact engine setup. Neither the Ford
diesels one or the Mondeo diesel one are very satisfactory.
But with the engine removed from the car, I have been able to start
having a good look at what will be involved in getting it into my
saloon.
There are a couple of bits attached to the engine which have me
puzzled.
The first appears to be some sort of diaphragm affair, on the top-left
of the inlet manifold.
I think it's probably responsible for opening/closing the exhaust gas
recirculation valve, which is below it.
This unit is leaking a little bit of oil. The unit doesn't appear to
come off i.e. if I need to replace it, I'll probably need to replace
the whole manifold, which will be a nuisance.
A single small-bore pipe runs from the upper casing of the diaphragm
to a plastic unit on the bulkhead, which in turn has a pipe which runs
to the brake serve vacuum pipe. I think this plastic unit is used to
switch vacuum to/from the diaphragm.
The plastic control unit seems to be electrically controlled (2 pins),
so what decides whether to open the valve or not? I thought this
engine had purely mechanical injection, but is there some processing
somewhere?
Or is it all done through simple electrical stuff like relays?
What would be the effect of simply removing the diaphragm, blanking
all the holes off and doing without EGR altogether?
Next up is an electromechanical device which was located under the
engine bay fuse box.
It looks like a plunger which presses against a hinged flap, which in
turn pulls a bowden cable which connects to a lever on the injection
pump somewhere near the throttle lever.
The plunger has a multi-plug connector with several wires to it.
Possibly some sort of anti-stall or cold start device, or for raising
the engine revs when reversing or changing gear? What is it? Do I
need it? If so, does it go to an ECU again?
There's a crank sensor mounted such that it would read lumps in the
back of the flywheel.
Very like the crank sensor from my Zetec/megajolt.
Would this be for the tacho input? If so, do I need to keep this
flywheel?
I hope not, I'm not sure if it's a dual mass one, or would be
compatible with the ERST gearbox/clutch.
I was hoping to use the ERST flywheel and an Escort/Fiesta clutch.
I've also spotted that one of the injectors has 2 thin black wires to/
from it.
Why would only one injector have/need wires?
I half-expected this to be the tacho feed, but it would run at 1/4
speed. So where would these wires go?
There's a multiplug connection to the air intake, 5 wires. I suspect
it might be something like a MAF sensor - the air intake has a square
plastic tube across it, which could easily contain a hot wire.
Again, why would a purely mechanical injection need a MAF sensor?
What reads the input, and what does it do with it? Another clue to
the existence of an ECU?
Finally, I haven't seen anything which looks like a method of
controlling the boost pressure.
Should there be one? I'm not looking to play with changing the boost
(not good on a diesel) but just curious.
Anyway, right now the electrical loom around this engine is looking
pretty daunting.
I'm hoping that a lot of the connections will prove unnecessary and
I'll be able to reduce the loom considerably.
Certainly, removing the various gearbox connections will help.
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