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New Engine at Last #606833
07/12/19 05:26 PM
07/12/19 05:26 PM
Joined: Apr 2017
Posts: 936
Staffordshire
IvorMog Offline OP
Talk Morgan Regular
IvorMog  Offline OP
Talk Morgan Regular

Joined: Apr 2017
Posts: 936
Staffordshire
At long last, I have finally replaced my old Silvertop 1.8L Zetec engine with a new crate 2.0L Blacktop Zetec engine. I've even updated my signature line on here.

Why?

Because I wanted the challenge and the new engine will give me a better base for future tuning work.

Although the 2 engines are very similar, it did present some problems to stop my now retired from useful employment brain from atrophying.

1 They moved the oil filter so it interferes with the right hand engine mount. I had to change which engine mounting bolts it used with a bit of cutting, grinding and welding.

2 The bottom hose and water pump is different and the inlet is a different size. The pump rotates in the opposite direction so an Idler is needed. Thankfully off the shelf at Retro-Ford.

3 Because of the water pump change, the alternator has to be moved to the other side of the engine. Again, Retro-Ford make a kit to do this but it then ended up very close to where the brake pipe goes through the inner wing and a whole clump of wires so modifications needed to make it work with a safe operating clearance.

4 The intake manifold is different so the vacuum take-offs for the MAP sensor and brake servo had to be modified to connect up. No kits available but not the biggest challenge.

5 The throttle body is different so it needed a new intake and filter system (which I'm still not happy with but it works) and changes to the throttle cable end.

6. I've used the 1.8L Silvertop flywheel which in effect is the same as a lightened 2.0L flywheel for better throttle response and acceleration. I used the old clutch so that will need looking at if I significantly up the torque.

7. The new Blacktop sump would not work with the standard gearbox bell housing and starter motor arrangement so I had to modify the old Silvertop sump to work on the Blacktop.

8. ECU mapping. The Blacktop uses different injectors and operates at 3.8 bar fuel pressure compared with 2.7 bar on the Silvertop. I had the flow rates checked for both types of injector and calculated what difference the pressure would make. (not linear but a wealth of data on the internet). I then modified an old Silvertop calibration to allow for the increased engine capacity and different injector flow rate.

This has all taken me about 6 weeks of intermittent work to actually do but many more weeks of thinking, planning and head scratching.

Yesterday I filled the engine with running in oil and fresh coolant and double checked (more like quadruple checked) everything. I had left the battery on charge overnight to make sure I had enough voltage for numerous engine starting attempts.

I offered up prayers to every God I could think of then cycled the fuel pump a few times to ensure full pressure in the unlikely event that the engine did start. I also hooked up the computer to the ECU to check all the vital information and provide some initial feedback from the data-logging

I turned the key and almost jumped out of my skin as the engine burst into life immediately on the first cranking attempt.

Don't panic I said, that's what was supposed to happen (at least in my dreams) but quick, check the oil pressure. Phew, 5 bar. Alternator charging Ok, rev counter (which works from the alternator) reading correctly.

I kept the engine between 2000 and 3000 rpm until the temperature started to get up to normal (another tick in the box, the revised cooling system seems to work) then with some trepidation I took my foot off the pedal and waited for the engine revs to die down and stall. To my great surprise and joy it didn't stall but sat nice and smooth at 950 rpm.

Engine now getting well up to temperature and the fan kicked in at precisely the correct temperature and then went off again at the hysteresis point. (Another tick in the box)

Turned it off and went looking for leaks but there were none and the computer logging showed that everything was working as it should although probably running a bit on the rich side.

Today I played with the fuel mapping and took some of the fuel out of the calibration to lean the mixture slightly but you can't really tell what it's doing on a static run up,. It was more of a gut feel at this stage.

So the BIG moment arrives. Time to get out on the road and see if it is actually drivable in the real world. I reconnected the computer, switched on the data-logging and turned the key. To my amazement it fired first time again so no messing around waiting for it to warm up, get out on the road and see what happens.

To my amazement ( I think I used that phrase before) it just pulled away and accelerated normally and even from that first moment I could tell this was going to be good.

I can already tell the throttle response is there and I'm sure I can feel much better bottom end torque.

After about 15 minutes I stopped to check the computer was not showing any untoward signs and had a quick look under the bonnet for signs of leaks or other nasties.

Started up again and set off on another lap of my test track and started to get a warm satisfied feeling as I gradually opened her up a bit more. Pulled out of a junction, 1st gear, 2nd gear, go on give it a bit more welly.

Accelerating smoothly at about 3/4 throttle then "OH S**T", the engine started to misfire. I lifted the throttle and tried again but no joy, it was still misfiring.

It wouldn't rev past 4000 rpm, it just kept misfiring. Then I remembered that I had set the rev limit to 4000 in case I had a runaway at start up and I had forgotten to reset it for the road test. "Stupid boy".

Pulled over, reset the rev limit to 6000 and tried again. Wow. Clean all the way past 5000 albeit only using 3/4 throttle.

So in this Christmas festive season It seems that dreams can come true so I'll get it on the dyno this coming Wednesday and give it a couple more hours of braking in then set about refining the fuel and ignition map.

At this stage I'll limit it to 6000 rpm and won't spend long sessions at full throttle but I am so excited as I'm convinced this engine is a big set forward for Mog

If only Brexit was this simple.


















Last edited by IvorMog; 07/12/19 09:39 PM.

Bob

1999 4/4 2.0 Zetec
Re: New Engine at Last [Re: IvorMog] #606837
07/12/19 05:31 PM
07/12/19 05:31 PM
Joined: Aug 2010
Posts: 2,674
Costock, South Nottinghamshire...
Paul F Offline
Talk Morgan Expert
Paul F  Offline
Talk Morgan Expert

Joined: Aug 2010
Posts: 2,674
Costock, South Nottinghamshire...
Sounds like someone has had a very productive few weeks.

Have you done anything to the brakes or suspension?


Paul
Costock, UK
2014 4/4 Rolls Royce Garnet Red
Disco 4
Teddy - 17h1 Irish Draught cross
Re: New Engine at Last [Re: Paul F] #606839
07/12/19 05:37 PM
07/12/19 05:37 PM
Joined: Apr 2017
Posts: 936
Staffordshire
IvorMog Offline OP
Talk Morgan Regular
IvorMog  Offline OP
Talk Morgan Regular

Joined: Apr 2017
Posts: 936
Staffordshire
Originally Posted by Paul F
Sounds like someone has had a very productive few weeks.

Have you done anything to the brakes or suspension?


Yes, refurbished the calipers, new rear slave cylinders and braided hose.

Fitted Suplex SSL front suspension. Panhard rod waiting in the wings.

Last edited by IvorMog; 07/12/19 09:31 PM.

Bob

1999 4/4 2.0 Zetec
Re: New Engine at Last [Re: IvorMog] #606840
07/12/19 05:37 PM
07/12/19 05:37 PM
Joined: Apr 2008
Posts: 8,170
Gloucestershire, UK
Hamwich Offline
Talk Morgan Guru
Hamwich  Offline
Talk Morgan Guru

Joined: Apr 2008
Posts: 8,170
Gloucestershire, UK
Well done Bob, sounds like a major success!


Tim H.
1986 4/4 VVTi Sport, 2002 LR Defender, 1957 R4 CV, 2005 Ferrari Vipar
Re: New Engine at Last [Re: Hamwich] #606843
07/12/19 05:49 PM
07/12/19 05:49 PM
Joined: Sep 2009
Posts: 4,422
Köln Germany
Heinz Online content
Part of the Furniture
Heinz  Online Content
Part of the Furniture

Joined: Sep 2009
Posts: 4,422
Köln Germany
Originally Posted by Hamwich
Well done Bob, sounds like a major success!

+1


'14 4/4 graphite grey
Re: New Engine at Last [Re: IvorMog] #606844
07/12/19 06:21 PM
07/12/19 06:21 PM
Joined: Jul 2007
Posts: 14,497
Suffolk
John V6 Offline
Member of the Inner Circle
John V6  Offline
Member of the Inner Circle

Joined: Jul 2007
Posts: 14,497
Suffolk
+1. Photos please .


JohnV6
2006 Indigo Blue Roadster S1
Re: New Engine at Last [Re: IvorMog] #606847
07/12/19 06:31 PM
07/12/19 06:31 PM
Joined: Sep 2011
Posts: 12,409
Mandello del Lario, Lake Como,...
Gambalunga Offline
Member of the Inner Circle
Gambalunga  Offline
Member of the Inner Circle

Joined: Sep 2011
Posts: 12,409
Mandello del Lario, Lake Como,...
Congratulations. It is a great satisfaction to achieve such a success. Was the ECU the original Morgan ECU or something aftermarket? I am fascinated by the fact that you were able to adjust the fuel map and log the ECU which, of course, I have done with the Omex ECU.

I am also a little curious as to why you did not fit individual throttle bodies while you were at it. Omex have kits available for the Blacktop.
http://omextechnology.co.uk/tb-kits-zetec-blacktop.html


Peter

[Linked Image]
Re: New Engine at Last [Re: IvorMog] #606849
07/12/19 06:37 PM
07/12/19 06:37 PM
Joined: Aug 2010
Posts: 2,674
Costock, South Nottinghamshire...
Paul F Offline
Talk Morgan Expert
Paul F  Offline
Talk Morgan Expert

Joined: Aug 2010
Posts: 2,674
Costock, South Nottinghamshire...
Originally Posted by IvorMog
Originally Posted by Paul F
Sounds like someone has had a very productive few weeks.

Have you done anything to the brakes or suspension?


Yes, refurbished the callipers, new rear slave cylinders and braided hose.

Fitted Suplex SSL front suspension. Panhard rod waiting in the wings.


Excellent stuff. When run-in, you will have a wonderful car. And it will still be the best kind of Morgan - a narrow 4/4.


Paul
Costock, UK
2014 4/4 Rolls Royce Garnet Red
Disco 4
Teddy - 17h1 Irish Draught cross
Re: New Engine at Last [Re: IvorMog] #606859
07/12/19 07:34 PM
07/12/19 07:34 PM
Joined: Jul 2019
Posts: 136
Surrey
K
Kevcaster Offline
L - Learner Plates On
Kevcaster  Offline
L - Learner Plates On
K

Joined: Jul 2019
Posts: 136
Surrey
Awesome
I’m totally impressed


Kevin

2009 Morgan Plus 4 4 seater
Re: New Engine at Last [Re: IvorMog] #606868
07/12/19 08:10 PM
07/12/19 08:10 PM
Joined: Dec 2009
Posts: 22,013
Devonshire
+8Rich Offline
Member of the Inner Circle
+8Rich  Offline
Member of the Inner Circle

Joined: Dec 2009
Posts: 22,013
Devonshire
Good work that man, well done thumbs


Regards Richard

1999 Indigo Blue +8
2009 4/4 Sport Green
1994 Connaught Green +8





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