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georgen

Well I bought this as a stop gap and to try out estate cars so I can carry my two dogs about, but once I drove it I fell in love with it so its stopping for the time being. My last 5 cars have being Vag and its a long time since I have owned a ford, the last was a immaculate sierra 2.8 4x4 which i still regret selling. before that mk5 escort, couple of basic sierra's couple of capri's one a 3.0L the other a 1.6 laser, a couple of mk4 cortina,s and the second car I ever owned was a mk1 Granada 3.0L ghia, my God what a car that was.

Anyway enough of memory lane here she is.

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The first thing I did was Clean the car and the engine bay, anyone who knows me will agree I hate dirty engines sorry I never took a before pic (fail on my behalf) 

 

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I then serviced the car, with new oil, air and fuel filters, a good quality fully synthetic oil was put in after a oil flush additive was put in old oil and ran.

Since then as I was looking into cambelt change times I noticed that at 108000 miles it had not been done and couldn't believe it wasn't due till 125000 miles so had that changed genuine belt and tensioner kit. 

 

I also debadged the remains of the Ocus badge and the tdci badge and opted to only fit a newer tdci badge back on.

A little mod I got from here was the windscreen nozzle change to mist type this this was also done.

To keep the dogs at Bay I sourced a factory fit type dog guard on preloved for £30 so was well happy as after all this was the reason behind getting a estate.

 

Another little mod also found on here was the new interior light with the mood lights in, I have this fitted but still have the wire to install for the lights to work so pics will come then.

 

Todays job was the EGR blank, another mod taken from this site and thanks a lot to Lenny for his top how to do it write up. I tried fitting it without moving my fuel filter but all i did was drop gasket and blank plate lol, so give in and removed the stupid cage around it and moved filter. 

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Looking at the blank plate its not a mirror image of itself so after looking at the egr and the blank decided to install it this way.

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Here is the cage from around the fuel filter.

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And finally the fuel filter moved to one side.

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Car seems smoother now and a little more torque y. 

Preee

Car looks great , nice and clean as well.

georgen

Well thanks to Clive the postman brought me a prezzie :) 

 

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b4zz

that looks a nice tidy focus you got there and looks like it has cleaned up a treat.

liking what you have done so far what other plans you got if any?

georgen

Not going daft so clean paintwork up, three spoke steering wheel, mudflaps, front fog lights, pos chrome front grill, If i found some leather seats at the right price <_< and might look at wheels after winter after all its a work horse and to carry my two dogs about.

georgen

Well was having a dig around my box i keep car bits in and came up with this, its a volt meter mounted in battery cover, first pic hard to see with camara, 2nd engine not running 3rd engine running, took 30 minutes from finding to pics  :D

 

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georgen

Found this in my box of tricks too but might be overkill  :P  :D

 

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georgen

Found this in my box of tricks too but might be overkill  :P  :D

 

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I was only joking about using this lads  :lol:, anyway the silicone joiners are the wrong colour for my car  :P

jeebowhite

Looking good George!

georgen

Well went and got some wire and wired up the ambient lighting on the interior light I bought.wired it to the light switch so once lights on they are on as well, wired to orange and blue wire going to switch, there was two and either can be used.

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jeebowhite

Looks good!

georgen

Well our lass has returned home so I put both cars in back lane and taxed the fog lights out of hers for mine  :ph34r:

 

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And here's one of both and a neighbors escort estate in the background   :)

 

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b4zz

both focus are looking good fella and imo they look better with the fogs

georgen

both focus are looking good fella and imo they look better with the fogs

 

Ill keep an eye out for some going cheap as I agree, hence why there now on my car not hers LOL.

jeebowhite

if my missus had a car (or could drive for that matter) and I told her I was going to nick something for mine, so mine looked better. I can guarantee I would be kicked square in the ghoolies!

georgen

if my missus had a car (or could drive for that matter) and I told her I was going to nick something for mine, so mine looked better. I can guarantee I would be kicked square in the ghoolies!

:o Well its either the Men are tougher up North and dont care what our other halves say Or we are completely Stupid  :P

 

Ps our lass is out so can type a reply like this  :ph34r:

jeebowhite

I am originally a northerner, the problem is, so is the wife! lol - I think braver and stupidity though (most certainly in my cicumstances) have a brave = 1 : 2 = Stupid ratio :p

georgen

Well this afternoon I tackled the bad key mark down the passenger side, from front wing through to rear door, I ordered some touch up paint off ebay and suprise suprise the shades miles out, but when the scratch is white anything darker going to look better :lol: . Well this is what I started with.

 

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Well started off filling the scratch with paint, I used a very fine brush but it always looks crap when it goes on, I built it up with two layers.

 

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Now the leap of faith when you dont have anything to measure paint thickness, and dont know the history of the car, you take 1200 wet and dry abrasive paper and rub it down using wet soapy water.

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I then repeated this again using 2000 grit wet and dry again with soapy water.

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I then used G3 cutting compound with the polisher and gave the wing, front door and rear door a going over, then to protect the cut paint I applied a coat of Harly's Wax to protect.

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Here is what I have you can still see the scratches as the colour wasnt a good match but it looks a lot better, and to the naked eye you arnt drawn towards them now, the camara as always picks them out well.

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This is my car and I wouldn't suggest you attack your cars with paint or sandpaper.  :P

Lenny
Once again mate,
You have done a fantastic job, looks like it never happend,
Nice shine off the paint work too,

Would ya not wave at the camera ?
:)
georgen

Once again mate,
You have done a fantastic job, looks like it never happend,
Nice shine off the paint work too,

Would ya not wave at the camera ?
:)

LOL, Ill wave next time Lenny, it would of looked a lot better if it was the right blooming colour, but it looks better by the naked eye hopefully this weekend get it all polished up and shiny weather permitting, not too hot or cold or wet :wacko:  

Lenny

LOL, Ill wave next time Lenny, it would of looked a lot better if it was the right blooming colour, but it looks better by the naked eye hopefully this weekend get it all polished up and shiny weather permitting, not too hot or cold or wet :wacko:  

Speaking of the naked eye, could always be worse ;)
. funny-ebay-advertisement-stupid-naked-pe

On a serious note though mate I think the carlooks great,
b4zz

great job you have done on the scratch fella looks a lot better then it did

Highwaymanuk
Fantastic looking estate mate. Love the colour and you've done a cracking job on that scratch.
georgen

Thanks Lads, your estate looks like its had some work Highwayman :)

missed a delivery today but an collect after 4 so I wonder what it is. :blink:

Highwaymanuk
Yeah mate only alittle bit. LoL As with any car enthusiast the project is never finished so still a fair bit to do!
Looking forward to watching the progress on yours!
georgen

Well went to the post office, luckily its at the top of my street :) 

this is what I got today, Ive had a nightmare getting hold of this for sensible money :) 

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More stuff to do this weekend then  :D

Highwaymanuk
Could've had mine if you'd found me a 4 spoke with CC buttons! ;-)
georgen

that will be a rarer beast to find me thinks  ;) , Got this one for £55 delivered including airbag so not complaining, just ordered the tuning box so we will wait and see what that does, it does come with a 30 day money back guarantee if you dont like so for the price of return postage its worth the risk. 

Highwaymanuk
Will you be selling your 4 Spoke airbag after you have fitted your 3 Spoke wheel?
georgen

I never thought about it, was going to keep to replace if I got shot, but with two focus's now I could swap over, could always swap for you three spoke one  :)

georgen

Well this afternoon I sorted the boot release switch, slight cheat as I fitted a new ford unit  :ph34r: , also fitted the new steering wheel. :)

b4zz

got any pics of the streering wheel

georgen

Fitted

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Highwaymanuk
Nice! Will let you know about Airbag swop!
b4zz

looking good

georgen

Well today the tuning box I bought arrived so I looked at the destructions that came with it and the nice colour pictures and thought No that's not where the sensor is LOL. so before we start, if you thought fitting a egr blank was a nightmare don't attempt this, you will get frustrated and end up wasting your time taking stuff off your car only to refit it again.

 

So anyway the common rail plug I had to disconnect on my 1.6 tdci focus is located above the starter motor and beneath the egr valve so in a really easy place to get at....NOT. first I had to remove the bracket that goes around the fuel filter by removing the five bolts, you will need a 8mm socket for this, you then lift the fuel filter and prop to one side without disconnecting the pipes.

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Now its time to locate the plug you have to disconect, the first picture below if you look at where the screw driver tip is the sensor is down there, on the second picture below I have moved the pipe holder and you can just see a bit red in the centre of the pic, this is the plug you have to disconnect.

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Now the problem here is when you put your hand down and under the pipework you can feel the underneath of the plug but you cant get your fingers on top of the plug where you need to be to release the catch on the plug to remove, so I bent a piece of metal so I could hook the catch so when I pulled the plug catch released allowing the plug to unplug. I tried for about 10 minutes without this and couldn't do it, here is a pic of said bent metal.

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It took about 2-3 attempts then it released.

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Now the tuning box has two wire plugs one male and one female and there are black not highly visible red so I first put some blue tape around plug so when I want to remove it, I will be able to see it easier.

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So of the two plugs from the tuning box one goes to the connector on the rail you have just removed the wiring plug from and the other goes into the wiring plug you have just removed, its as simple as that, you then secure it in a sheltered position using cable ties and refit what you have removed.

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Took car for a spin it has more power and pulls smooth and consistent but does not give the gains the manufacturer claim, there is no smoke so for what I paid for it cant grumble and at least my clutch will last longer than it would have if it was an aggressive tuning box. 

Lenny
Looks like a nightmare to fit mate,
That fuel bracket has become your best buddy in recent times lol I've got a brand new from ford metal one of it, if you ever want it, says its part of the engine cover mounting, but I never fitted it, was stable enough without it.
I'll time you with a stop watch, you must be an expert at removing it by now ;)

Have you noticed an increase in MPG ?
Also your gains would increase with a Green Cotton induction filter fitted or similar type of free flow induction,
Not sure if you had one fitted yet or not.
georgen

Looks like a nightmare to fit mate,
That fuel bracket has become your best buddy in recent times lol I've got a brand new from ford metal one of it, if you ever want it, says its part of the engine cover mounting, but I never fitted it, was stable enough without it.
I'll time you with a stop watch, you must be an expert at removing it by now ;)

Have you noticed an increase in MPG ?
Also your gains would increase with a Green Cotton induction filter fitted or similar type of free flow induction,
Not sure if you had one fitted yet or not.

Box not been on long enough to tell mate but I've complained about there exaggerated claims and there dodgy installation guide, I have told them where it is located now so should help others down the line LOL,In reply to my complaint they have asked for the serial number so watch this space, I haven't got a performance filter yet but will get one when funds open up a bit as still trying to sell megane so her focus was funded with the only spare cash I had. on the bracket front it is a mount for the cover which I dont have but as I am used to removing now and refitting only takes a minute lol

FOCA

Try resetting the ECU - that can help the performance as the ECU will have "learnt" from when the 'box was not fitted, now that the box IS fitted once the ECU is reset the ECU will set the parameters (fuelling etc) for that  

 

Is the tuning box adjustable? does it have different settings/ maps etc? if you can turn it up you can usually get a bit more power out of it - i have simple techniques i can let you know about to set up the tuning box to optomise the power/ acceleration with the minimum amount of wasted fuel etc

 

As Lenny has said, the air filter often makes a noticable difference, on a turbo car it can help the engine respond quicker/ more power at low revs (especially before the turbo spools up) even a new, pattern filter (i can pick ones up for mine for £6) is better than a old, choked one,(when did you have yours last changed) and can improove MPG too

 

Ive been doing a lot of research on air filters recently and although the green cotton filter is expensive,(and usally more expensive than the K&N), it is better than the K&N, because 1 - the green colour means you can tell it is dirty, you can't so well on a K&N because the K&N filter material is black/ dark  2 - the green cotton filter uses a better method of bonding so there is less "bleed" onto the filter element, this, along with deeper pleats, results in a larger surface area (for a given filter size/ application), compared to a K&N or stock filter, which can increase airflow/ reduce  through the filter - the K&N and green cotton use a similar type of oiled cotton filter material, it flows better than a paper filter but does not filter as well (tiny dust particles can get through, especially when the filter is new) that is why i use a stock/ pattern filter but change it every 6 months/ 6k, but i have a cool air feed in the wing that picks up a lot of dust via an opening near the front/ left wheel, once i redesign/ relocate this to behind the grille i plan to fit a green cotton filter myself at some point (remember this is all "academic" if the filter itself is not the most restrictive part of the induction system- small tubes before the filter box may be more of a "bottleneck"- in that case you may as well fit a stock or pattern paper filter and change it frequently)  

 

the tuning box increases fuel so its important that the air is not restricted with an old/ clogged air filter      

 

Often with a tuning box it boosts the low- end and midrange torque - the performance improvement (on a diesel) can be very deceptive - you often don't notice yourself qoing quicker instead everything else seems slower - the torque/ power curve may now be diifferent and you may be quicker changing up at lower revs - eg 3.5k (to keep it in the torque) or using a gear higher than normal (eg, for overtaking) - i agree "they" often egzaggerate? power/ torque figures but would you have bought it if it claimed (for example) a 12HP  gain? (when all their competitors are making ridiculous claims and punters might buy one over another because it clains slightly more power? )

 

Thats a great tuning box fitting guide and you should copy it out as is and add it to the "guides" section   

georgen

My air filter is a pattern one but new, I always service a car when i buy it even if its just being serviced, i am generally hard on cars but I do pamper them at service, the leon used to get £20 oil put in then dumped after 10 min running, then oil filter and long life synthetic oil put in but oil and filter changed every 6k, of course I wont go to that extreme with the focus diesel but it has got a decent oil in it. and was flushed first. dont like oiled filters as they tend to take Mafs out but do like ITG and pipercross ok too. the leon had a cold air feed and I used to find gravel in the airbox lol, with the focus 3.5 k is higher than i would normally change gear more high 2k-3k as its different with 90 bhp as opposed to 240ish bhp.  :blink:, the box isnt adjustable as in past if you can turn it up you will max it out  :D and as the old saying goes no smoke no poke  :P. they might not do anything but you never know, I bought a german one as my last box was german and spot on so we will see what happens. :unsure:

FOCA

My air filter is a pattern one but new, I always service a car when i buy it even if its just being serviced, i am generally hard on cars but I do pamper them at service, the leon used to get £20 oil put in then dumped after 10 min running, then oil filter and long life synthetic oil put in but oil and filter changed every 6k, of course I wont go to that extreme with the focus diesel but it has got a decent oil in it. and was flushed first. dont like oiled filters as they tend to take Mafs out but do like ITG and pipercross ok too. the leon had a cold air feed and I used to find gravel in the airbox lol, with the focus 3.5 k is higher than i would normally change gear more high 2k-3k as its different with 90 bhp as opposed to 240ish bhp.  :blink:, the box isnt adjustable as in past if you can turn it up you will max it out  :D and as the old saying goes no smoke no poke  :P. they might not do anything but you never know, I bought a german one as my last box was german and spot on so we will see what happens. :unsure:

There is some debate as to whether oiled cotton filters (Greeen Cotton, K&N etc) actually contaminate MAF sensors, K&N claim theirs do not, and it is only if they have been over-oiled (by the user, after cleaning) that this happens, (this was tested by K&N - so you can take it with a "pinch of salt")  my car does not have a MAF so it does not effect me anyway

 

Other filters like Pipercross etc (dry foam) cannot contaminate MAF sensors with oil off the filter element, and have been found to flow better than stock paper filters, but at the expense of filtration - thier seems to be a link between filtration efficiency and flow restriction within the filter and if you want a free- flowing filter you may have to compromise filtration efficiency (smaller particles of dust get through to contaminate the engine that would not get through a stock (paper) filter)

 

i could not find the power/ torrque curves/ plot for the 90HP 1.6, but here is the 110HP -

 

http://www.mybluefin.co.uk/curves/focus16tdci110bhp.pdf   

 

As you can see the peak power of the engine is at 4100rpm, so that is the best revs to change gear, for maximum acceleration, no point in revving it higher (than 4100rpm with the engine on the graph) "through the gears" or changing up earlier (at lower revs) (this is called "short shifting") - if you change up at 2k or 3k you are slowing the car down (unless your peak power is at 3k- which is unlikely)  

 

You will accelerate faster if you change up on your peak power - it is nothing to do with whether you have 90, 240, or 1000hp, but at what revs peak power is made  (on the engine (tdci 1.6/110) on the graph, its 4.1k)  

 

There is lots of misinformation about things like this on the net - for example, there were some "experts" :lol: on another forum  that thought they would accelerate faster if they missed out gears ("block" shifting) like 1st to 3rd to 5th, complete rubbish!   :lol:  :lol:  :lol:

 

It probably won't surprise you if i told you ive plotted the acceleration in every gear and set the boost, and all other settings, as well as the optimum speed and revs to change gear - on mine its 3.6k, (for now- and its a "low revving" 2.0L TDDI with stock turbo & injectors) if i changed at 2 or 3k, it would slow the car down - a lot. 2 or 3k is ok for "crousing" or economy, but if you want your car to "shift" - time your changes right  (changing at peak power)    

georgen

I dont shift when i do because I think its the peak power, think its just getting used to diesel engines again, the tdci is a noisy bugger over 3k and at 90 bhp isnt going to set my world alight so whats the point. one thing I noticed is you class bhp as peak power but infact torque is the measurement that moves any mass from a to b, and it spikes at about 2400 rpm. bhp is nothing without torque, thats why theres diesels out there that worry some fit cars.

georgen

Well got reply from box company today, they asked me to open it up and change settings from 4 to 3, I did this to no marked difference so I have reported back to them as asked.

here is what it looks like inside, all i need now is the complete list of settings.

[URL=http://s400.photobucket.com/user/georgengwen/media/focus/003_zps0a70b78f.jpg.html][/URL]

georgen

Well being bouncing a few e-mails back and forth about the tuning box, and found out, what ever one switch is on the other has to match, also each position up equates to 1.5% increase alternatively down is 1.5% aswell. apparently some cars are more/less sensitive than others so I have to play with settings and if I am still not happy they will gladly have a look at my unit for repair, replace or full refund so cant be any fairer than that.  

Lenny
I've just spotted you digital volt meter built in to the battery lid mate looks good,
georgen

I've just spotted you digital volt meter built in to the battery lid mate looks good,

Where you been Lenny, that was weeks ago LOL

FOCA

Well being bouncing a few e-mails back and forth about the tuning box, and found out, what ever one switch is on the other has to match, also each position up equates to 1.5% increase alternatively down is 1.5% aswell. apparently some cars are more/less sensitive than others so I have to play with settings and if I am still not happy they will gladly have a look at my unit for repair, replace or full refund so cant be any fairer than that.  

Often, the distributors of the tuning boxes are not the manufacturers (+ English is not their 1st language) 1 box may fit several different vehicles or similar engines but with different specs (eg 90, 100, 120PS versions of the same engine) - exact models may not even have been tested (by the companies themeslves) so the tuning box makers set the boxes on a "conservative" setting and/ or rely on their customers' feedback to help them choose the right settings

 

With the feedback from customers being unreliable (inconsistant results due to different conditions / driving techniques)

 

(eg - if the engine produces 90hp at 4k, its probably less than 70Hp at 3k, and even less at 2k)

 

+ performance can be very subjective - you can be going slower and if feels faster and vice- versa

 

So the box must be set up with scientific precision  -preferably on a dyno but can be set up "on track"  the conditions must be the same each test and timed accurately- randomly changing the settings without testing it properly is liable to make it worse

 

The tuning box can be set up for optimum power , economy or a balance between the 2- if yours is the type that increases the common rail pressure, if it is turned up too high it can put the injectors/ seals under un- nessesary stress - there is a point at which the performance is "maxed out" (the "sweet spot") but the box can be adjusted for even more pressure - (putting the injectors/ seals under un-nessesary stress) - to find this point takes knowledge, patience and precision

 

Before you set the box up you must find the best revs/ changing points to get the most out of the engine-  this is to optomise the box for best performance,  but also, of course an "underpowerd" car needs every hp/ advantage, compared to a powerful one

 

PS - you may need the reset the ECU for any changes you make to the tuning box to take effect          

georgen

Well I haven't adjusted the box away from the setting it was delivered with, and this £40 of diesel lasted 272 miles, not bad since I have kicked its puddings in a bit since finding out it has a dpf lol. I am going to drive a bit more normal for this £40 worth and see what I get.

Lenny

Well I haven't adjusted the box away from the setting it was delivered with, and this £40 of diesel lasted 272 miles, not bad since I have kicked its puddings in a bit since finding out it has a dpf lol. I am going to drive a bit more normal for this £40 worth and see what I get.

Sounds good George,
Get the dpf internally removed, will give you more torque, high end boost and 0.4 km per litre of a fuel increase
georgen

Sounds good George,
Get the dpf internally removed, will give you more torque, high end boost and 0.4 km per litre of a fuel increase

When it needs it mine will be getting emptied completely ;)  



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