Purchasing List
GENUINE sump gasket Exhaust studs Exhaust heat nuts + spring washers Inlet manifold gasket Exhaust manifold gasket – fiesta rs turbo Mechanical Fuel pump blanking plate gasket
8mm Fuel line
Oil (10w40?) Filter Sump washer
Coolant
Rough Tools guide: Definitely required 10mm socket 13mm socket/deep socket hex 17mm socket hex 7mm socket for jubilee clips 10mm spanner 13mm spanner 19mm spanner
Timing light
Optional: Stanley knife for silicone hoses Drill & Welder for the sump
First things First:
Double check the above lists, make sure you have all the tools/spares/time/etc cos once you start it’s a pain to go back. So do you feel lucky? Well do you punk?
…disconnect the battery, easy 10mm socket (stop now if this is causing grief!)
…remove the bonnet, as it just gets in the way (four 10mm bolts at the front, get someone to help lift the bonnet and support it while you undo the bolts, try not to scratch the bonnet too much! And don’t let it drop!
Getting messy…
Start by draining the sump. You want to run new oil for your new turbo so might as well let it drain off now…
While its draining, remove the starter motor. To do this, disconnect the wiring clip from the alternator and remove the feed from the battery. Undo the 3 13mm headed bolts and drop it out of the bottom of the car.
Then drain the coolant from the radiator. For the more gentile among you there is a drain plug in the bottom left corner (view from sitting inside the car looking at rad), or yank off one of the bottom hoses if you feel a little more brutal.
Once all is drained remove buckets so that you don’t drop anything in the oil!
Inlet manifold side:
Basically, this has about 6nuts holding it on, all 13mm get a good ring spanner to do this so you don’t burr them up. Undo the engine lifting eye (drivers side) and the mechanical fuel pump (passenger/dizzy side) You shouldn’t need to remove the carb from the manifold, but make sure you detach everything before pulling the manifold/carb off (Fuel lines/vacuum hoses/anit-run-on solenoid etc.)
Exhaust Manifold side:
Undo the join of the exhaust downpipe to the exhaust system, which is toward the rear of the engine bay. Undo the manifold from the head, about 8 or so 13mm bolts. I would advise using a 13mm hex head socket rather so there is no chance of burring the bolts up. Some will come out on the threads so replacing these with new threads is best (see purchasing list).
Be patient, if the bolts go tight, relax get some wd40 and pray you don’t snap them!
If all is well and you have undone them, continue.
If the car is jacked up high enough you should be able to remove the manifold and the downpipe as one, up through the engine bay. This saves time and also the risk of damaging components that can be sold on or saved for another day…
Remove the radiator, although not essential its worth doing to protect it from being punctured. Its so simple, two 10mm bolts at the top and the hoses off course (fan should come off still attached)
Distributor: Disconnect the ignition leads from the spark plugs. Remove the king lead from the coil. Remove the old distributor by undoing the two 10mm bolts and pulling the distributor from the head.
Sump: If you are using the original xr2 n/a cvh block then you will need to add a turbo oil drain. (See above) Remove the old sump, by undoing the 14 or so + bolts. Remember the 4 in the corners. To gain access to the gearbox side, remove the cover plate at the bottom of the gearbox.
See SUMP SECTION for details on the sump
Clean up the new sump mating surface make sure it is free from any debris. Carefully attach/glue the GENUINE FORD sump gasket to the sump. Carefully, (a second person is very useful here) slide it up into position. Bolt it up following the correct sequence which can be found in the Haynes Manual for the fiesta. The bolts don’t need to be done much more than hand tight. Use a torque wrench if unsure and quote the manual for the correct setting.
Have a beverage – Tea/beer, because that may have been tough!!
Fuel Pump: Attach the fuel pump to the crossmember/firewall beam as shown. If this is not the desired location or an alternative pump is being used, then seek alternative fitment solution. Lengths of Fuel lines will need to be adjusted to suit.
Oil Feed:
Remove the oil pressure switch, insert… adaptor into the engine block, dowty seal, banjo bolt/hose dowty seal
then screw the oil pressure switch into the end of the adaptor.
You could use some red loctite thread sealant (suitable for high temperature oils) to seal the threads.
Oil Filter:
Remove the old oil filter if you havent already done so and replace with the new oil filter.
Return Fuel line:
Remove the return fuel line from the underside of the car. Disconnect it from the engine bay and undo it at the rear. Special fasteners hold the lines in place along the underside of the car.
Replace with a fuel feed line, or for a neater factory fit, bend up a new line using fuel piping as mentioned in the first section. Secure in place. Drop the fuel tank by undoing the four mounting bolts. Slide down off the fuel filler pipe. Remove the fuel return line and replace with 6.5mm line to join to the new return hose (8mm). Replace the tank, drain out some fuel if it is heavy, (easier if almost empty). Slide it diagonally up the filler pipe and rotate and align the holes.
Turbo Technics Exhaust manifold: Attach the Turbo Technics exhaust manifold to the engine using the new exhaust studs, spring washers and heat nuts. Use a new mk3 fiesta turbo gasket for cvh engine.
Attach turbo: Attach the turbo technics t25 turbo to the exhaust manifold. Ensure that you take care and keep the inlet and outlet ports of the turbo covered to prevent objects from entering the turbo (dirty/oil/nuts/spanners!!) Connect turbo oil feed and oil return
Attach exhaust elbow and downpipe: Attach the turbo technics exhaust elbow to the turbo exhaust port using the four spring washers and 4 heat nuts. Connect the downpipe to the bolt using the four m10 heat nuts and spring washers.
Connect to exhaust system: Connect the downpipe to the xr2 exhaust system using the special spacer ring and tensioner assembly. Secure the xr2 exhaust pipe in place on its hangers and connect the new middle hanger.
Attach Fuel pressure Regulator: Attach this to the little bracket that holds the brake line going across the engine bay (directly behind the carb)
Attach inlet manifold/carb: Attaching the carb/inlet manifold is reverse of removal, ensure you use new gasket when installing.
Non-Return Breather: Connect the non return valve to the breather port and to the bottom of the filter. Connect the other side to the rocket cover, as per the normal xr2 cvh engine
Attach/Move radiator&Fan: The radiator has to be moved over to allow the turbo to be fit. As a result, the fan will foul the top radiator hose. Turbo Technics drill a new hole to move the radiator over towards the passenger side to allow fitment of the turbo. The Turbo Technics cars had a square section cut from the corner of the fan, to allow it to clear around the hose. This is all using you own judgement, and it is best to install a slim line fan (Pacet/Kenlowe/Spal/Peugeot fans). The fan does NOT need to be move to the other side of the radiator and WILL fit if the rad is moved slightly to avoid contact with the actuator port.
Attach Vacuum advance/retard Distributor: Fit the new sealing washer/o’ring to the distributor and install the distributor into place.
Fitting Plenum chamber: 3 bolts attach the plenum chamber to the top of the carb, it can only go on one way, so don’t force it! The rubber seal should be fitted around the rim of the carb prior to fitment of the plenum. If you don’t have one, use a bead of mastic or silicone sealant. Fit Overboost Switch This is connected to the plenum chamber and is used to prevent overboosting in the event of actuator failure. It is screwed into the chamber. Electrical connections will be documented later.
Fuel Pump Blanking Plate: Fit the fuel pump blanking plate with the gasket.
Intercooler: Install your choice of intercooler now
Piping up: Air in turbo: Connect a suitable air filter to a piece of 64mm Silicone hose and attach this to the compressor housing inlet.
Air out turbo: Connect a piece of silicone pipe from the outlet port of the turbo/compressor housing (pointing vertically upwards) to the inlet of your intercooler.
From the other port of the intercooler connect using suitable hosing, to the plenum chamber.
(if you want to run a dump valve see DUMP VALVE section) (if you want to run a boost gauge see BOOST GAUGE section)
Connect a vacuum hose from the distributor to the back of the carb. Connect a vacuum hose form the fuel pressure regulator to the plenum chamber
Connect Fuel lines…
Feed Line to Pump Pump to Regulator Regulator to Carb Regulator Return to Return Line
Replace spark leads
Replace main coil lead
Replace Starter Motor – 3 x 13mm bolts
Fill With oil
Fill With Coolant
WIRING:
Attach the mounting bracket for the inertia switch. (if your kit doesn’t contain one, use one off any injection ford – escort/ka/fiesta
The basic circuit is as follows:
The fuel pump takes a supply from the anti-run-on solenoid on the carb. It goes through a 20amp fuse. Then it enters the inertia switch/fuel pump cut off switch, then goes to the pump. The pump is earthed to the chassis.
NOTE: The anti-run-on solenoid on the carb needs to be connected as usual so don’t cut the wire.
The overboost switch is in series to the black lead of the ignition coil. Cut the coil and join each side of the cut to the overboost switch using two lengths of wire.
That’s it, nice and simple.
Take your time and construct a good loom with good quality and correct rated wire.
PRE-START CHECKS
All hoses securely attached? Everything visibly connected? Check fuel hose connections Have you filled up with oil & water?
Any spare parts still left over? Sounds daft but if you have a pile of bits you havent put on yet then you’re not ready to go starting it!
Connect battery when you are ready! Crank her over and fire her up! Let it run for a bit, then turn it off and check for leaks/etc
Set timing at 8 (??) degrees advance
Go for a rag!
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