Pinto into Mk5 = LEZ Compliance

[robbie.cee]

Hi Tim, long time... hope your well. Any news on the Essex plates?? mounts too i guess!!

piccies please when your ready

[dieselhead123]

Hi Tim, long time... hope your well. Any news on the Essex plates?? mounts too i guess!!

piccies please when your ready

A 'mock-up' Essex to MT75 adapter has been made, this is now with my 'computer man' for conversion into an appropriate CAD file for water jet cutting. We wanted to do as much of the development as possible 'in-house' to keep the cost down.
We will be using the standard V6 Essex flywheel and starter motor to simplify 'part acquisition' and will supply engine mountings and a power steering pump mounting that enables the existing Di power steering pump and pipework to be used, (as we did for the Pinto).
Once we have an adapter plate made, we will fit an Essex in the 'Surrogate Mother' and produce engine mounts etc.
The only additional part required will be a 'twin' pulley for the crankshaft to drive the power steering pump.
Pictures will be posted in this thread once we get going
TIM

[simon3314]

any help DOHC fitted to a transit mk5

Fancy taking it out so I can have a better view

https://picasaweb.google.com/1114236188 ... 7691654674
Here's one on LPG... In my opinion Ford made a tangled dogs dinner of the inlet manifold area. The production line must of hated it. It all looked very daunting until I disassembled it all and realized that there's not that much to it.

So I'm extending and re-routing some wiring and fuel pipes with ergonomic connections . There's so much space to play with under these bonnets.... I discovered a loose LPG pipe which l just clipped into the underside of the inlet manifold. It all looks really cheap. I guess that's what Ford are good at! ....It no doubt was letting excess air in and affecting performance...So Will re-work that lot I think... Cleaned up fuel rail in the foreground..Cleaning the manifold at the moment...... The lump and gearbox is going to get treated to a steam clean etc. Then new components going on, water pump, alternator etc, and good soak and flush with Calgon or similar before it all goes back together with a new Rad.

[robbie.cee]

Thats love!!!!! good show!

best start ordering my gaskets etc eh Tim??

[simon3314]

hi there
i have a dohc 2.0lt 8 valve engine in my 98 transit (aus)
am after a engine part supplier who deals in these engines
require piston,rings and bearings etc to overhaul motor
also chasing workshop manuals to suit

The chap that works with me downloaded a Ford Sierra Haynes manual from the internet, it covers the 2.0 dohc 8 valve engine, I can get him to send you the link tomorrow, or today your side of the world
If you are really stuck for parts, pm me and let me know what you need and we will price up for you, not sure how the postage charges would work out to Aus but happy to help another Forum member

Tim

Hi there... I found this post so thought I'd get in touch.. I'm in the process of replacing the Di in my 190 with a factory fitted LPG 2.0 DOHC from a donor van that I have in my yard. However I'm finding it hard to source the odd part such as a new downpipe and I also want to get fresh engine mounts, (just the circular rubber bits that are encased in a steel ring). Can you point me in the right direction at all please?.... Cheers Simon

[dieselhead123]

Hi there, how old is the van that you intend fitting the DOHC in? Mk3/4 use the same engine mounting rubbers across the range.
How old is the donor van, the one with the DOHC in?
The Mk5 models have different engine mounting brackets.
I am sure that the mounting rubbers are available 'pattern'.
The DOHC exhaust downpipe will be available from good motor factors, you should be able to get this by quoting the reg of the donor van.
Please feel free to call the works number in the morning and we will do our best to identify the parts you require, using the vehicle reg is the easiest method. Alternatively, pm me the vehicle details and we will check our supplier's applications for you.
Do note that the DOHC uses a different gearbox to the di, the bell housing case is different, so you will need to swap gearboxes as well.

TIM

[layalog]

mmmmmm i keep looking at a 4.6v8 in my shed but that old pinto would do just aswell ive been thinking of this for a while not for emisions and all that but maybe cheaper to run. i will be interested for sure im not getting a later van they seem to be a little stressed. martin

[robbie.cee]

mmmmmm i keep looking at a 4.6v8 in my shed but that old pinto would do just aswell ive been thinking of this for a while not for emisions and all that but maybe cheaper to run. i will be interested for sure im not getting a later van they seem to be a little stressed. martin

mmmmmm 4.6 TASTY!!!

[dieselhead123]

Some changes have been made to the Pinto PAS bracket that allows the 2.5di PAS pump to be fitted to the Pinto engine.
The original, although perfectly ok did pose access problems, it was necessary to remove the bracket in order to gain access to the fuel lift pump fixings. Also, as these were manufactured from 2.5di brackets, we were regularly running out of stock, we never had enough 2.5di brackets to modify!

A new design of bracket is now available, it consists of an 'adapter' bracket that fixes to the existing threaded holes in the Pinto engine, allowing the customer's own 2.5di PAS pump bracket to be bolted to threaded holes in the adapter bracket.
Some pictures below;



This is bolted to the Pinto block as below;



Note, it is now possible to remove the fuel lift pump with the bracket in place

This new bracket does require the customer to modify their existing 2.5di PAS bracket prior to fitment.
The 'leg' on the back of the 2.5di PAS bracket, this came across the front of the 2.5di engine, bolting to the engine front case, needs to be removed as in the picture below;

This can easily be accomplished with the aid of an angle grinder.

The now modified 2.5di PAS bracket is next fitted to the bracket we supply as below;



The PAS pump is now fitted to the original bracket as below;




The only other point to not is that a slightly shorter PAS pump drive belt is required, the 'next size down' will normally suffice.

Those of you who have recently purchased the new bracket will be able to refer to the above to aid installation.

These brackets will continue to be available at the same price, £45 plus postage.

TIM

[layalog]

very neat tim like it.

[robbie.cee]

Yes top stuff mate!

[layalog]

all seems quiet on the western front tim hows that conversion going.. im still looking around for a good lump .

[robbie.cee]

any more on the essex matey?

[dieselhead123]

Yes Robbie, some news;
The first 'Master Adapter' is awaiting collection from the profile cutter, this will need some more machining by ourselves, some holes need threads cut and some need countersinking.
I am awaiting an order of UNC fixings to enable the plate to be fitted to the rear of the Essex engine, unfortunately I think my supplier may still be mining the iron ore to manufacture these from
I have also been working on a Pas bracket and twin pulley arrangement to allow fitment of the 2.5di pas system to the Essex block, similar to the Pinto set up, (you will notice on your engine that there is NO twin pulley). This utilises commonly available Transit parts to simplify the conversion.

Hopefully there will be some pictures for you all to look at by next week

TIM

[robbie.cee]

cool stuff mate!!!