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St220 Powered Mk1 Ghia


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141 replies to this topic

#11 refriedgenes

refriedgenes

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Posted 25 January 2013 - 06:39 PM

While there was space I replaced both the front brake pipes and removed the aircon radiator and ATF oil cooler. The first problem I encountered with the manual conversion was the fact that unbeknownst to me, the automatic uses a different subframe. The rear gearbox mount uses a different system. Out came the welder and a bit of old gearbox mount from a type 9 gearbox. After a bit of in and out with the new engine and setting up the best position I could I managed to stick this to the rear of the subframe.
rear engine mount smaller.jpg
It's shown here with the box already attached. Bit of hammerite to keep the rust at bay.
Craned the engine out and finished the welding. And then spent a couple of hours in about the most uncomfortable position I could ever imagine; head up in the drivers footwell and legs draped up the back of the drivers seat with all the blood going to my head and all the cramp to my legs, to finish up with this
correct number of pedals smaller.jpg
Thankfully, the mounting points for the auto pedalbox are the same as those in the manual, and there's just a rubber grommet to remove from the bulkhead where the master cylinder protrudes into the engine bay.
Craned the engine back in again, hopefully for the last time in a while.
st220 engine in 2.jpg st220 engine in.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.....

#12 refriedgenes

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Posted 25 January 2013 - 07:18 PM

*
POPULAR

Now it pretty much looks like this
all in finally 4 smaller.jpg
The wiring side proved less of a headache than I originally thought. You just leave this unplugged.
auto plug.jpg
But, it turns out that the Auto needs to think that the car's in either Neutral or Park before it'll start. Had a read through Haynes circuit diagrams and found out that this connection is made at what was the auto gearbox position sensor. Initially I just soldered the 2 wires together and wrapped them back up. This was until I took it out again and it wouldn't rev over 4k. It wasn't struggling, there was just some kind of limiter occurring. Had I read the owners manual that still came with the car after all these years, I'd've realised that it won't rev highly while it's in Park/Neutral to protect the engine when not under load. I'd fooled it into thinking it was in Neutral all the time.
This seemed as good an excuse as ever to have a simple push-to-make starter button that you press when turning the key which momentarily tells the ECU the car is stationary. It's also quite good anti theft but I've just broadcast it to the world so that's the end of that.
starter button smaller.jpg
I needed to swap the brake master cylinder too as the automatics didn't have a takeoff for the hydraulic clutch. This led to quite an interesting maiden voyage. I only went round the block but what I now know to be defective seals in the old master cylinder wouldn't let the fluid travel back when I eased off the brakes. So every time I touched the brakes, they came on even harder. It was relentless. I had to leave the car a couple hundred yards from the house for an hour or two while the fluid drained back. I limped the car home carefully and replaced the master cylinder and servo with one from a breakers and now all is well (ish).
  • maulokk likes this
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.....

#13 Simonty

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Posted 25 January 2013 - 07:25 PM

This is bloody brilliant, best thing I've seen on here in a long, long time! Genius :D

Old: 1997 Mk2 Si 2.0, 1996 Mk1 Ghia V6, 2002 Mk3 Zetec-S 2.5 V6, 2003 Mk3 Ghia X TDCI
Now: Saab 9-3 2.0 turbo with mods!


#14 4x416v

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Posted 25 January 2013 - 07:27 PM

nice work
<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>

#15 sgking

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Posted 25 January 2013 - 07:41 PM

what a surpise thread! been waiting years for decent coverage of this 3.0 lark.

you write well too. nice one!
Mondeo 2000 ST24

Mondeo ST200 Limited Edition no 181/300 'Ghia X'

#16 siruncle

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Posted 25 January 2013 - 07:51 PM

Nice project mate, you'll get there mate, i remember doing a auto to manual conversion (a week after a 1.6 to 2.0 conversion on my old mk1 sierra, rip) pedal boxes were a direct swap on that, and the sierra had the starter inhibitor switch to stop it being started in gear, the wires just twisted and got soldered together, instant fix, so you were on the right tracks... Only the electrics went on to some electronic microchip as opposed to the old on off switch "chip" in the sierras.

Don't envy you out in this weather doing bits to it!

Keep up the good work, and the updates :L

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02 zetec-s 2.5 in Panther Black and an 05 Fiesta St150 in colorado red

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#17 Simonty

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Posted 25 January 2013 - 07:56 PM

you write well too


Doesn't he just?! A refreshing change on a car site, superb to read.

Shame you're up in Grimsby else I'd be trying to invite myself over for a gawping session :eek13:

Old: 1997 Mk2 Si 2.0, 1996 Mk1 Ghia V6, 2002 Mk3 Zetec-S 2.5 V6, 2003 Mk3 Ghia X TDCI
Now: Saab 9-3 2.0 turbo with mods!


#18 Mal

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Posted 25 January 2013 - 08:48 PM

Brilliant thread.. Can't wait for the next installment.

ST220 55plate Saloon Final Facelift in Performance Blue.

 

Honda Civic 1.8 Vtech Executive.

 

Triumph Street Triple..aka  'The Hooligan Machine'.

 


#19 roomey

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Posted 26 January 2013 - 10:29 AM

Cracking stuff really enjoying this tread keep up the good work, I love to see the rs body kit on it then
Cheers
Roomey
Petrol petrol petrol their is no other fuel!!!!!
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Mk4 mondeo 2.5t titanium x Mk3 mondeo red zetec s v6 ,mk2 mondeo 2.5 v6 st24 hatch light blue, mk2 mondeo 2.0 ghia x estate green, mk2 mondeo 2.5 v6 ghia x saloon green, mk2 mondeo 2.0 lx auto hatch black, ford capri mk2 gl 2.0, 16lx sierra hatch cream

http://www.talkford....mk3-zetec-s-v6/

#20 Nick

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Posted 26 January 2013 - 10:54 AM

Brill, haven't had a decent engine swap for a very long time! The 220 is a great engine, I've often thought of putting it in a Mk1 Mondeo, but as always, time and space!

Interested in finding out what all the crypto currency fuss is about and why so many people are making thousands of pounds?

 

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