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Steve’s FW 2.0 Zetec build – January 2021


SteveB21

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SteveB21

Fitted the ECU panel this afternoon. Decided to set the hinges up so I could slide the panel off if required in future. 

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Riveted the panel hinges and tapped the chassis dash rail for M5 screws - no idea why this picture is upside down!

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Bent the end of the panel round the chassis rail using a mallet and a length of soft wood:

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No going back now - stock check day tomorrow and then the fun really starts!  Bodywork and seats are for collection at a later date.

Both floor panels on today:

Big day Saturday - chassis off the build stands and onto axle stands. Did it with 4 helpers plus attached the engine crane at the rear just in case... All went OK, so now I need to tidy up the wiring

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SteveB21

Been tidying up a few bits & pieces, including the harness around the engine bay ahead of getting the engine & gearbox fitted.

 

Fuel tank vent hose fitted, with tie-wrap holding it on the vent nipple:

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Fuel tank level sender wiring fixed in place, connectors as per S250 manual:

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Foam strips fitted to battery tray and battery dropped in - still can't find the strap for the tray... 

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Lots of sleeving fitted to the main harness and engine harness along with loose cable ties.  Connected up the brake fluid level sensor and brake pressure sensor.  Probably got as far as I can without fitting the engine to finalise the cable runs. Leaving the scuttle plate loose until then.

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SteveB21

Retreated to the kitchen today to stick some Dynamat to the tunnel top panels and the passenger side outer panel. Left the section where the gear stick hole will be until later, after I have made the hole:

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Fitted Dodomat to the visible front section of the outer panel, matching the footwell end panels:

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Finally, found my reverse light switch was coming apart, so have asked Westfield for a new one:

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SteveB21

Just one small job to report - fitted the speed sensor connector to the speed sensor cable and tested the connection through to the speedo connectors.

 

Connections as follows:

+12v supply = harness green = sensor brown

Ground = harness black = sensor blue

Signal = harness yellow/white   = sensor black  

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All worked OK, with sensor lighting up when a bolt head passed in front of it (thanks @Ian Kinder (Bagpuss) - Joint Peak District AO for that tip) and signal at the speedo connector:

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The sensor wires are very thin and fragile, so will have to be careful of them as other connectors get fitted.

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SteveB21

Ran the wiring for the battery charger / power socket today, connected to a splash proof fuseholder on the chassis leg next to the battery. Decided to run the wiring direct to keep the current loading off the harness power connection. Will terminate with a connector behind the dash and then fit a power socket post-IVA.

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SteveB21

Spent some time today checking the engine over before, hopefully, fitting it over the weekend. One small job became a big job - who decided to use a Torx T40 socket for the oil pressure grub screw?? My cheapo Torx set was clearly not going to shift it, so off to Halfords for a T40 star bit on 3/8" socket drive, which did the job in seconds. Guess you can never have too many tools...

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Load leveller attached:

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Benrobson2999

Exciting times :) 

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SteveB21

Another job ticked off today - fitted the handbrake “seal” with M6 screws:

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Yorkshire_Pudding

Nice work @SteveB21, you might want to think about painting your handbrake lever as bare metal in the open atmosphere won’t last long. I know you won’t ever see it but just a thought 👍🏻

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SteveB21

Successful afternoon - engine & gearbox fitted. Had 3 helpers, which made it easy to guide everything into place. Followed the manual, used a load leveller on the engine crane and had it all fitted within an hour.

 

Before:

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After:

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Not much else to add really!

 

 

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SteveB21
6 hours ago, Yorkshire_Pudding said:

Nice work @SteveB21, you might want to think about painting your handbrake lever as bare metal in the open atmosphere won’t last long. I know you won’t ever see it but just a thought 👍🏻

 

Yes, I was thinking about that - I'll probably spray it with ACF-50 before I box everything up.  Thanks!

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Benrobson2999

Nice work. I think that’s the first big hurdle done :)

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SteveB21

Forgot to mention something yesterday in the excitement of having got the engine in - as other build diaries have mentioned, there is no need to drill the gearbox mounting plate for the Type 9 gearbox. The 2 parallel slots are aligned with the holes in gearbox mount.  I used penny washers under the M8 nuts due to the slots:

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SteveB21

Did gearbox oil-fill today - as others have found, it only took just over 1.1 litres. 

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Made a start on the various engine fittings and didn't get very far - there is no way the fuel pressure regulator will mount on the engine block and allow the connector to fit onto the throttle position sensor.  I have various photos showing this but the the TPS seem to be fitted with a much smaller connector in them.  @MikeJG I see you ended up with your regulator on the chassis opposite the alternator.  Did this create any issues further on in the build?  Another option seems to be to fit the regulator at the back of the engine block and swap the hoses over so the fuel feeds the injector rail from the front - anyone see any issues with this?

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Steve Smith - AO Hampshire And Isle Of Wight

Take a look at my build diary on how I fitted fuel reg and how I turned the TPS through 180 degrees. Page 14/15

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