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St220 Powered Mk1 Ghia


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141 replies to this topic

#1 refriedgenes

refriedgenes

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  • Vehicle Driven:Bora TDi, MK1 Mondeo
  • Name:Dave
  • Location:lincolnshire

Posted 25 January 2013 - 01:30 PM

Hi,

I used to run a Mk1 24v manual hatchback in nouveau red in which I did 50k odd (relatively) trouble free miles. I loved the fact that it was essentially a base model with a manual sunroof and winding windows in the back, but with a stonking V6 under the bonnet with a tone that you could play like a Stradivarius. Unfortunately rising fuel costs and the fact that my girlfriend at the time lived 90 miles away meant that when it started to make funny noises I raided the piggybank for a 2001 VW Bora Tdi. The VW hasn't missed a beat and the midrange torque is brilliant but I still mourned the rev range of the V6.

I never actually got rid of the Mondeo and it sat on my mothers drive for nearly 4 years, still started occasionally just to keep it free.

Bought a house.

With a garage,

Fast forward to 2011 and I finally (to mother's relief - bless her) moved the Mondeo to mine.

Ebay, (other internet auction sites are available), and 550 hard earned quids turned me into the owner of the engine out of an ST220 that had suffered a rear ending. I was a tad apprehensive as all the other 220 engines at the time were £1000 upwards so what had I bought?!

Saddled up the trailer and my brother (he was for company, not to pull the trailer) and went to Birmingham to pick it up. Was a full engine with all belts and ancilliaries and a gearbox to boot. Pulled it home. Sadly I have no pictures of the V6 powered trailer.

So armed with Haynes' finest and a set of old clothes I about removing the old 2.5 out of the Mondeo.

I was without a camera at this point, so there's no photos, but I swapped the gearboxes over (my car was rod change, not cable), and used some old bits of exhaust pipe to make the 220 precats mate up with the old Y pipe. (I wanted to try and make this project relatively quick and cheap)
(pics are retrospect, sorry about the sepia)
modded front header to meet Y pipe.JPG
front header modified for Y pipe.JPG
and the rear
rear header modified 2 smaller.jpg
rear header modified smaller.jpg

More to come.
96 24v Ghia
3.0 Manual conversion running but not perfect
Debadged dewoodtimmed
Si/Mk2 Zetec 16's - (still the prettiest IMHO)
Wait til i get the mk1 Escort finished.....

#2 Docterozlo

Docterozlo

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Posted 25 January 2013 - 01:44 PM

Now this sounds promising and please put more pics up !! :D :L

Edited by Docterozlo, 25 January 2013 - 01:44 PM.

1996 corsa b - sold,1996 civic lsi -sold,2001 mondeo zetec - sold, Toyota celica vvti current car

my old build diary
http://www.talkford....8-zetec-mondeo/

 

 


#3 4x416v

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Posted 25 January 2013 - 02:16 PM

cool project, a 3.0 Mk1 would fly!

Whack some St200 cams in there which are a direct fit for that top end surge.

Regarding remapping, explore the avenue if it's possible to 'Flash' an existing ST220 map direct to your ECU, if not possible I recommend the likes of megasqirt stand alone management.

Looking forward to this diary and development. :L
<p>Mk4 Mondeo tdci 140 Zetec</p><br />
<p>Mk3 Mondeo Final facelift 2.0 Titanium</p><br />
<p>Mk3 Mondeo Final facelift 2.0 Ghia X</p><br />
<p>​​Mitsubishi Pajero 2.8td</p><br />
<p>My old Mk1 4x4 diary:<br><a class="bbc_url" href="<a href='https://www.talkford...0#entry1497480'class='bbc_url' title=''>https://www.talkford...80#entry1497480"</a>title=""><a href='http://www.talkford....80#entry1497480</a><br>' class='bbc_url' title='External link' rel='nofollow external'>http://www.talkford....480</a><br></a>

#4 refriedgenes

refriedgenes

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Posted 25 January 2013 - 03:04 PM

I needed to change the alternator over and use the old one. I believe the ST220 alt is regulated by the ECU and my old EECIV management isn't prepared for that. 1st snag, was that the engine blocks are slightly different in this respect, and to mount my old alternator I needed to cut a small lug off the block near the top. Out comes the grinder. Alternator now fits.
Being that the air con had never worked since I'd had the car and I'd never had it regassed, I decided to do away with the extra radiator and all the plumbing, which then meant I could lose the pump as well. I'd never realised how heavy they are, here's the space it left behind.
air con pump removed 2.JPG
Obviously it required a shorter belt.
New shorter belt sourced.
Turns out the timing covers differ between the engines and there's a raised section on the 220 one right in the path of the shorter belt.
Turns out to swap the timing cover I need to remove the rocker covers, power steering pump, idler, tensioner, crank pulley, and the sump.
Cue swearing and a trip to Fords to try and navigate their parts department. I don't know if you've ever tried to buy things from a Ford parts department, but it's sometimes as if they haven't had the concept of vehicle parts explained to them.
Turns out that whilst my guy was friendly and willing to try without a registration number, he initially refuted my claim that Ford had ever made a V6. :darn:
We persevered, and a fortnight later I possessed the rocker gaskets, timing cover gaskets, and a crank pulley bolt.
Set about removing the crank pulley, the edges of which gave way under my 3 legger. Nice one Fords! Fortunately I had the spare from the old engine which seemed a lot more robust. Swapped the crank seals over, (which in hindsight was probably a stupid thing to do) and the timing covers and bolted it all back together after a good clean.
Thing are looking up.
Turns out the injector loom that goes under the UIM is missing from my engine. Tried the old one from the 2.5 and the spacing and injector plugs are different.
Things are looking down again.
Mulled over the idea of using the old injectors for a moment of brain freeze and quickly ditched the thought.
40 quid lighter and a few days later I now possess the correct injector loom. I was amazed to find that after a riveting morning testing continuities along the wires that the pinouts on two of the large plugs at the back of the engine hadn't changed in 7 years and 2 model upgrades.
Things are looking up, again.
The Mk1 uses a return type fuel system where the pump supplies the engine with whatever it needs and sends whatever's left back to the tank.
The ST220 uses no such rubbish.
Things are looking down, again.
Thought about swapping to returnless style but then realised not only would I need the ST220 pump, but I'd also need the management system that drives it, which basically means sourcing then swapping entire looms, not to mention ECU and all the immobiliser stuff too. Not likely, says I.
A few long nights spent in front of the Google machine led me to a post on the http://www.fordconto...-fpr-connector/ site (apologies to the mods - if you want me remove reference to another site I will) which basically ended up with me having this
fuel pressure reg.jpg
I cut the FPR off the old 2.5 rail with a hacksaw and took it to my local friendly engineer who tapped it so I could fit some barbed fuel line fittings and a T piece, so that now the ST220 fuel rail has a return capacity.
Essentially this. The red lines indicate that everything behind the pressure reg is under pressure and the return line to the tank is indicated in blue.
fuel schematic.jpg
So that's fuel and exhaust sorted, on a budget. Out comes the crane, in goes the engine and gearbox. Connected all the pipes up, filled it full of oil and water. Battery, intakes, steering fluid, bled the clutch, started it up.
No-one was more amazed than me that it worked. Things are looking up.

Edited by refriedgenes, 25 January 2013 - 03:07 PM.

96 24v Ghia
3.0 Manual conversion running but not perfect
Debadged dewoodtimmed
Si/Mk2 Zetec 16's - (still the prettiest IMHO)
Wait til i get the mk1 Escort finished.....

#5 refriedgenes

refriedgenes

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Posted 25 January 2013 - 04:15 PM

Very gingerly, I put my foot on the clutch and put it into gear, and very, very slowly lifted my foot up to the biting point. As the gearbox started to take the strain, I ran out of pedal.
Things are looking down, again.
If I floored it in gear, the car started to move, oh so slightly. There's nothing quite like sitting on your drive in your car in top gear at 3k. Back to Talkford searches, and it turns out you need to match the flywheel to the gearbox not to the engine :dang:
I drained all the fluids, disconnected the battery, all the pipework, the driveshafts, undid all the engine mountings, the exhaust and the gearbox selector rod and lifted the bloody thing out again.
You can see the difference in flywheels here:
flywheel comparison 2.jpg
flywheel comparison.jpg
The 220 one is obviously a dual mass thing and this hadn't registered when I swapped the gearboxes over. Split it down again and swapped the flywheels and clutches so I was now running my original one from the 2.5.
Wrong clutch
wrong f'n clutch(!).jpg
Right clutch
mk1 clutch on.jpg
A more prudent man might have put a new clutch in it while he was there, but I figured I'm getting quite versed in this engine removal lark, so when it goes, I'll tackle it.
Gearbox bolted back up, starter motor back on while it's all out and easy to get to, and the captive bolt on the starter that attaches the power lead shears off with very little force at all. Things were looking up, momentarily.
Good job I don't throw things away, I used the old starter and all is now fine again so I set about refitting it all, engine in, pipes, fluids, electrics, driveshafts, gear selector, fuel lines etc. Amazingly, it started again, 2nd turn of the key. Things are looking up, again.
I'd always known that the body required a little attention at the rear of the sills but I have a mig welder so I wasn't particularly concerned. I was kind of aiming for slightly rat look anyway so occasional patches covered in hammerite weren't a problem. I jacked up the car and had a good look at the sills.
Things are looking down, again.
I knew sills were available from the local auto factors at a reasonable rate but this plan assumes there is metal to weld them to, which was no longer the case. Under the carpet half the floor was missing. I quickly realised this was going to be decision time, I dropped the car down back on it's wheels and went on the pi$$. I came to the decision over the next week or so, that to weld up that shell would require removing the interior and the fuel lines, brake lines, fuel tank to be safe, wiring looms, and half the suspension, which knowing me, I'd want to rebush it all and get it powdercoated before I put it back on. This was quickly evading the project maxim of quick and cheap.
Fast forward a few weeks and I find myself on ebay during a nightshift and this baby pops up:
ebay1.JPG
96 24v Ghia
3.0 Manual conversion running but not perfect
Debadged dewoodtimmed
Si/Mk2 Zetec 16's - (still the prettiest IMHO)
Wait til i get the mk1 Escort finished.....

#6 refriedgenes

refriedgenes

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Posted 25 January 2013 - 04:38 PM

On the back of these pictures I put in a maximum bid of £500
ebay 2.JPG ebay4.JPG
ebay genuine mileage.JPG ebay broken bumper.JPG
ebay as henry intended.JPG ebay steering wheel and wood trim.JPG
The listing said it had decent bodywork, 81k on the clock, and service history. And it was a saloon, which I actually prefer when pushed.
£450 and I won it. The slight hindrance of having to travel from Grimsby to Bridport (Wales? No, Dorset) to pick it up was solved with another guilty pleasure of mine, riding on trains. I threw some basic tools and a multimeter in a rucksack and set off down south. On reflection I'm glad I didn't get searched when I changed at Euston as they'd probably accuse me of some nefarious activity. Got to Bridport about 2pm (been travelling since 5am) and met the chap, Michael. Nice fella. He gave me a tenner back to get some benzine which I thought was nice.
The car drove home without hiccup, and the only things that weren't working was the passenger side front foglight and the alarm didn't disable when using the drivers side to unlock the car. It wandered a little under heavy breaking but it's only a Mondeo if it requires the bottom arms replacing.
Perfect.
Apart from the fact it's an Automatic :dang:
I hate Automatics.
.
96 24v Ghia
3.0 Manual conversion running but not perfect
Debadged dewoodtimmed
Si/Mk2 Zetec 16's - (still the prettiest IMHO)
Wait til i get the mk1 Escort finished.....

#7 Docterozlo

Docterozlo

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Posted 25 January 2013 - 05:26 PM

It's a good thing that mrk1's are very cheap these days :) , will you be putting the manual gearbox into this one ?

1996 corsa b - sold,1996 civic lsi -sold,2001 mondeo zetec - sold, Toyota celica vvti current car

my old build diary
http://www.talkford....8-zetec-mondeo/

 

 


#8 refriedgenes

refriedgenes

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Posted 25 January 2013 - 05:52 PM

So I removed the engine (for the 3rd time) and drivetrain and all the good bits off the old shell and then called the local scrapyard who came and picked it up. By this time I'd inherited a camera, admittedly a cheap one that came free with something else.
I added my original 5 spokes
front end.jpg
It's got proper glass lense headlights
proper glass headlight.jpg
All important sills are good as are the rear arches
ns sill.jpg os arch.jpg
os sill2.jpg
It actually came up quite well after a good wash and a MOP with some G3.
ns bodyside.jpg os bodyside.jpg
While I was at it, since the wheels had been going flat every few days I decided to get them blasted and powdercoated. I went for white, in a vague kind of half arsed nod towards the old touring cars of the 90's. The main part is I'm no longer pumping the tyres up twice a week.
osr btcc wheel.jpg
I think it needs lowering really but that can happen when coilovers turn up at the right price, and anyway, some bits need to come off.

Edited by refriedgenes, 25 January 2013 - 05:54 PM.

96 24v Ghia
3.0 Manual conversion running but not perfect
Debadged dewoodtimmed
Si/Mk2 Zetec 16's - (still the prettiest IMHO)
Wait til i get the mk1 Escort finished.....

#9 refriedgenes

refriedgenes

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  • Vehicle Driven:Bora TDi, MK1 Mondeo
  • Name:Dave
  • Location:lincolnshire

Posted 25 January 2013 - 06:11 PM

Once the old car was gone and it stopped raining, it was time for the Auto to meet it's fate. I must admit, the comfy leather seats and the hi spec of the Ghia did kind of suit a lazy V6 auto, but that's not what I want, so after a few hours (it's getting faster every time I do this) I was left with one of these
car been sick.jpg empty bay.jpg
and one of these
2.5 auto train 2.jpg 2.5 auto train.jpg
After a few more hours I also had one of these
auto gearshift.jpg
and one of these
auto pedals.jpg
96 24v Ghia
3.0 Manual conversion running but not perfect
Debadged dewoodtimmed
Si/Mk2 Zetec 16's - (still the prettiest IMHO)
Wait til i get the mk1 Escort finished.....

#10 4x416v

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Posted 25 January 2013 - 06:18 PM

Petrol blue 'D5' like my Mk1 saloon was. If you need some ideas check out my Mk1 diary in my signature link.
<p>Mk4 Mondeo tdci 140 Zetec</p><br />
<p>Mk3 Mondeo Final facelift 2.0 Titanium</p><br />
<p>Mk3 Mondeo Final facelift 2.0 Ghia X</p><br />
<p>​​Mitsubishi Pajero 2.8td</p><br />
<p>My old Mk1 4x4 diary:<br><a class="bbc_url" href="<a href='https://www.talkford...0#entry1497480'class='bbc_url' title=''>https://www.talkford...80#entry1497480"</a>title=""><a href='http://www.talkford....80#entry1497480</a><br>' class='bbc_url' title='External link' rel='nofollow external'>http://www.talkford....480</a><br></a>




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