MK6 SWB Cosworth YB Conversion!

[Luke]

just had some stuff to do anyway.....................

One of the front - ignore the pipes been neatened now



close up on the engine



and one of the pipe



apart from that it's a pritty standard looking van

[intransit89]

you should do a video clip of it runing luke

looks like its made to fit in the mk6

[100 T280]

[rover]

If it wasnt blowing the pipes off in the Sierra then i has to be something you've done since

Is the wastegate working? Spring overtensioned?

How much difference is there between the internals of the intercoolers?

Rover.

[Luke]

really the only differences are

1. airfilter now k&n style strait on turbo
2. crank case pressure drain to sump not there on rwd sump so pipe blocked and also the pipe that went to the air box now just sits in the engine bay
3. intercooler same but pipes to and from are a lot longer so overall volume is incresesed quite a bit
4. wastegate pressure control pipe now direct - did go to some valve thing that i didnt know what it did (proffesional eh? ) but we've put this back on to try
5. has a brake servo pipe now

as far as the crank vent - i need to find out how its done on the rwd and copy that
also the pipes we've joined the intercooler up with dont have a lip on - that would help them hold more pressure

we cant see the wastegate opening but can you unless its under load????

hopefully stu will turn up today with a boost gauge - we can fit it and go from there

it's all good fun - i'm actually quite enjoying it we'll get it to north weald for sure and all everyione can stick there head under the bonnet - i'm sure together we'll have it sorted

[rover]

I assume the valve you are on about was a dump valve of some variety? If it had one before then it probably needs one.

How is the servo connected? The servo works from negative manifold pressure but the turbo creates positive manifold pressure so there is no vacum to activate the servo

The intercooler pipes will blow off quite easily without a lip on them, the easiest way to create one is with a cable tie cut to length and bonded in place with epoxy resin, used to do this a lot on Montego/Maestro turbo conversions

Rover.

[Luke]

I assume the valve you are on about was a dump valve of some variety? If it had one before then it probably needs one.

it's not the dump valve - ive got that on just before the throttle butterfly - infact you can see it in the second pic - red anodised thing not really sure what this valve is/does its a 3 way on the wastegate actuator - might be an overboost or something looks standard ford
i'll try post a pic of it

How is the servo connected? The servo works from negative manifold pressure but the turbo creates positive manifold pressure so there is no vacum to activate the servo

ive got it connected to the plenum after the throttle butterfly - it seems to be working although its not got a 1 way valve in the line i'm assuming its actually in the servo as it seems to work ok and hold the vacuum even when the turbo is boosting

The intercooler pipes will blow off quite easily without a lip on them, the easiest way to create one is with a cable tie cut to length and bonded in place with epoxy resin, used to do this a lot on Montego/Maestro turbo conversions

neat idea - i think thats what we'll do as i dont have access to a swaging machine (yet )

[transitgeoff]

looks quite easy to lower the rear an inch or 2

[Guy88]

servo should be befor the turbo

[Scotty86]

Looking good mate - good job

[Luke]

looks quite easy to lower the rear an inch or 2

well spotted they can come out but i think it will need to go some more

[Ford Sprung Van Tastik!!]

Nice conversion Luke , and done in quick time too

[Luke]

seem to have sorted the pipes blowing off problems - refitted the 3 way valve thing and now we are getting 12 psi boost - was only getting 6psi with it bypassed

got a boost gauge btw (stole it off my escort)

but now we have another problem - it seems to be intermittently (most of the time) running on 3 cyls rough tickover and low boost - ive tried a plug in each of the leads and we get a spark from each one we also unplugged each injector as it was running and they all seemed to be working - next step is to pull the plugs and see what they are like

but i thought to help us i'd wire the rev counter up seeing as it's a 2min job (i thought) - connected the green coil wire to pin 8 (white/black) of the large plug and it didnt work what have i done wrong also tried the mondeo set we have and they didnt work either

[coconut]

Ref the rough idle, had a similar problem when me and my mate put a volvo T5 lump in his pug 106, it turned out to be to much fuel pressure on idle causing the fuel to airrate (not to sure how to spell that, gets air bubbles in the petrol) and start missing, found this by when it starts to miss/run rough, press the valve in on the fuel rail (not typical H&S I know ) and relieve some of the pressure, fitted and iline regulator, and no more probs since

That 3 way valve thingy, is it a bleed valve maybe not to sure what they do but ive seen boy racers gone on about them

PS, you and Stu are the kiddies , its the only petrol mk6 i would want to own

[Luke]

fuel pressure had crossed my mind earlier on as we are running the transit DOHC pump - we had talked about fitting a fuel pressure gauge, but it's not a 2 min job so it didnt get done
also thinking about it this has a variable regulator controlled by the boost/vacuum in the plenum and thats something we've messed with (pipe to it) so i'll give it a look over tomorrow

i just put it on the ramps and i had to have 3 goes - not enough power to get it on

its the only petrol mk6 i would want to own

that means a lot to me mate