Sierra 3d Ecoboost

Jaanus · March 11, 2022, 19:49:04

Well lets put some info here about this project of mine.

Started off as a basic 1.6, didn't even get a windshield

Did some minor rust repairs. Just the most obvious hole in a fender and swapped on better doors, that i got with the car.

Also "rebuilt" a 2.0 pinto, new gaskets, rings, bearings. And got a disc brake rear axle.

And that about covers the first part :D

Jaanus · March 11, 2022, 20:09:38

A while later, saw an ad of a ń engine for sale. Friend of mine was selling his duratec out of a Mondeo, which he had rebuilt, so i bought it.
but not just rebuilt, slightly modified
CR 8,7:1
oversized Mazda turbo pistons
head works(valve seats, head surfaced)
crank polished and new bearings

So these engines come FWD in EU.
Finding RWD parts can be tricky, or expensive aftermarket.

First up, the sump:
The insides of a FWD sump

Ford Ranger 2,3l pickup and sump from the US

Cheapest option i guess

Same 2.3 Ranger, the water outlet from the back of the engine. Also the dipstick and tube

Back of the engine, the water outlet and egr blanking piece. Didn't know it at first, but There is a small hole behind that blanking plate, egr cooling, that need to be blocked off better than just a piece of metal

And here are the clearances at the back. Tight as always..

Jaanus · March 11, 2022, 20:20:27

Now for some aftermarket.
Bellhousing for a type9

Lightweight Flywheel

Engine mounts made myself

some extra room for the sump

Starting to make an intake. On the FWD intake, the throttlebody is at the back of the engine and it wont fit.

And before going further with that, here's the exhaust

yep, stuck a turbo on it

Jaanus · March 11, 2022, 20:30:56

So anyway, first try:

Second try, after getting a RHD coolant tank

Ditched the power steering pump to gain room for the intake. Fitted an electric PS pump, Oil catch can.
Oil drain from turbo, AN fitting welded on the sump.

Oil filter relocation plate from Mountune, has 2 small ports, one for sensor, other for turbo oil feed

Fuel rail from Mountune, VAG coil mounting

Jaanus · March 11, 2022, 20:36:25

clutch from Retroford.

water outlet tapped for a coolant sensor, also got rid of the metal pipe that the ranger has and made a flange on the outlet, to bolt on new pipe, rather than having an O-ring fit there, as it was real pain to get them apart if needed

Shortened the distick and tube by almost 10cm

Jaanus · March 11, 2022, 20:42:40

Direnza rs500 style intercooler and radiator

Exhaust, 3" stainless front to back.

Jaanus · March 11, 2022, 20:49:28

ECUMASTER Classic to this show

Some gauges

And some "experts" to try and get it running

Gettting an actual guy to come and make sure we don't blow it up:

Jaanus · March 11, 2022, 21:14:16

That was last August, when i got it running.

Since then i've blown up 2 7" diffs and fitted a 7,5" diff on 7" beam, just cut one mount off and welded it to fit the 7,5" diff

Also gathered some parts
MX5 NC 5 speed gearbox

clutch disc for the MX5 spline

Mx5 prop

outside diameter is the same as the Type9, but spline is different

Mx5 intake with DBW throttle.

and dbw gas pedal

Gave the engine more room, also to help with installing/removing engine with the box attached

gearbox mount made, using the Sierra box bushing

Gear lever sits at an angle, because in a MX5 the engine is tilted at an angle

Jaanus · March 11, 2022, 21:25:22

And this just about sums it up for now.
Took the engine out over the winter, stuck a pinto in it to get a MOT done.
was working on getting the DBW stuff fitted, changing the ECU to get the DBW working etc, to get a prop made out of the sierra and mx5 one.

But now, today went and picked up a new engine.
A 2.3 ecoboost

2018

Needs some work. Has a slight bearing knock

Block looks like the duratec. the duratec bellhousing fits

And if i get rid of the balance saft cartridge, then looks like the Ranger sump will bolt up to it

Jaanus · March 12, 2022, 07:19:40

Also:

Pinto weighs 160kg + type9 40kg

Duratec with the MX5 box 155kg

capri v8 driver · March 20, 2022, 11:43:58

Keep the good work up!!

Jaanus · March 20, 2022, 21:26:26

Quote from: Jaanus on March 12, 2022, 07:19:40 Also:

Pinto weighs 160kg + type9 40kg

Duratec with the MX5 box 155kg

Adding to that:

3,7 v6 150kg (no intake/exhaust, flywheel, clutch, etc)
MT82 60kg

BOB (no clutch/flywheel) 200kg

Jaanus · March 20, 2022, 21:39:40

took out the balancing shaft cartridge from the ecoboost and first bearing pieces picked out of the pickup

No3 big end destroyed, crank needs machining:

Also needs new main bearings:

Little bit of clearencing for the 2.3 oil pump and the ranger sump bolts on

However, these repairs will need quite a bit of money to get done and new parts ordered. So I'll leave it now and get back to it in the future. Not to mention, a standalone ECU able to run Direct Injection is in the range of 2k.-+

So that with that plan on hold, stuck the Duratec back in and welded up the propshaft. Sierra prop with the mx5 front spline and a sleeve machined to align them

capri v8 driver · March 21, 2022, 09:22:55

Quote from: Jaanus on March 20, 2022, 21:39:40 Not to mention, a standalone ECU able to run Direct Injection is in the range of 2k.-+

Ford already mentioned to stop with direct fuel injection as there isn't much advantage over a normal fuel injection and the cost of direct injection parts.

With most conversions the direct injection is removed and the intake modified to accept normal fuel injectors.

Jaanus · March 24, 2022, 10:55:29

While it would make things easier,
The intake is plastic, adding injectors to that would be difficult.
Making one from scratch would be the way.
And while you can see that i made the intake for the Duratec, it was easy, because injectors are in the head not the intake.
Also if one would go for port injection, then might get rid of the high pressure fuel pump, but that is driven off the exhaust cam. And to bolt a blanking cover instead of the pump would require to cut that part off the cam.. Thats if you dont have the room for that in the firewall.

Considering how tight the Duratec is in the Sierra, i can see that if i'd want the ecoboost, i'd have to move the heater blower away and cut into the firewall to clear the HP pump.

Jaanus · May 08, 2022, 15:28:45

Got new wheels

Fitted dbw throttle to my plenum, also new wiring and ecu.

Took it out to tune it on the road

Jaanus · May 08, 2022, 15:33:55

Was all nice and well, did 2-3 gear pulls on the highway.

Got back in to town, tried lauch control off the lights.. thats when it happened:

Jaanus · May 08, 2022, 15:39:08

In addition to the broken rod, another one was bent

timing chain tensioner broken

there is a small bolt in the timing cover, no idea of the purpose of it.
previous guy who built the engine must have tried to put a longer bolt there. resulting cracking the tensioner blade.

Anyway. stock rods don't hold any power

capri v8 driver · May 08, 2022, 15:50:47

Not so good. Did you found out what caused it?

Jaanus · May 09, 2022, 17:56:50

1bar of boost, small turbo, lots of torque down low, weak rods.

I've ordered rods and pistons for the ecoboost. In addition to the spun bearing, there was a bent rod in it aswell.

capri v8 driver · May 10, 2022, 08:46:06

Quote from: Jaanus on May 09, 2022, 17:56:50 1bar of boost, small turbo, lots of torque down low, weak rods.

I've ordered rods and pistons for the ecoboost. In addition to the spun bearing, there was a bent rod in it as well.

I have seen several stock 2.3 on 1 bar of boost and higher staying together for a long time. The one that i did see fail was a engine witch already made a lot of miles before putting a bigger turbo on it and broke one of the pistons. Having this said. The rods used in a stock 2.3 aren't the strongest and do fail. Check your block for cracks.

Maybe the launch control was not setup properly looking at that vid??

Jaanus · July 05, 2022, 20:39:39

filling unnecessary holes and a bit of fresh paint

Jaanus · July 05, 2022, 20:41:57

testfitting ecoboost. intake barely fits

replacement for the direct injection:

And now with that port injection kit fitted, the intake won't fit

capri v8 driver · July 07, 2022, 10:58:37

Quote from: Jaanus on July 05, 2022, 20:41:57 And now with that port injection kit fitted, the intake won't fit

Thats is easy to solve. I made a remote brake fluid reservoir. Can't you use the aluminum intake?

Jaanus · July 07, 2022, 20:05:26

It also hits the brake fittings.
It's different than duratec and I want to keep oem manifold for keeping it stock looking, If i choose to make it a legal swap.

I have now sent the engine to get built so can't really do anything related to that

capri v8 driver · July 08, 2022, 07:24:35

Its plastic intake so you could remove some of the fins that are sticking out and then heat it up to push a dent in the plastic.

A other option would be to off set the brake booster. But it looks on the pictures that the front brake line fittings have clearance. Its just the fitting on the rear that needs to be chanced/altered.

Jaanus · July 10, 2022, 14:32:10

We'll see when i get the engine back. Nothing to do until then.

Maybe trim some ribs off, but i'm hesitant about heating the intake. I dont want to blow up that manifold :D
Even that aluminium intake, 3mm material thickness bent.

capri v8 driver · July 10, 2022, 19:42:02

Its just plastic. If you are careful with applying the heat you can easily bent plastic in the shape you want.

Just practice on a old broken plastic intake.

Jaanus · July 10, 2022, 21:08:24

i have some fwd duratec manifolds i can try on

Jaanus · October 21, 2022, 18:12:10

Saw this one up in an auction, bought it with info only from the pictures :D
1.8 carb Power, looks decent for the price. Only someone has put mk2 side blinkers on the wings

and one wing is rusted because of that.