fiestaturbo.com

[daz]

most turbo repair shops will no longer warant any claims against a t2 turbo unless the oil return pipe has been modified.
the reason been is the low angle it returns to the block, as well as having a smaller bore pipe, so with the infrequency of oil changes, these often start to get blocked, leading to oil going back past the turbo seals and then putting pressure on the top hat behind the exhaust impellor wheel which then wears it out, also allowing for oil to be pushed through the intake system.
here is a few pic of what i have done to modify mine.
first of all i got a escort t3 oil return pipe.

see the difference in width of bores between t2 and t3 oil return pipes.

the flange was then cut off both the t2 and t3 oil return pipes, the fiesta flange hole is to be opend to 14mm at this stage, the t3 flange is binned.


cut the remaining t3 pipe in half and invert the straight pice.

now line up the curved piece on the sump and the straight piece on the flange and mark where you want them to be welded.


i left aprox 2" inbetween the two oil pipes to reduce the risk of snapping any welds, hence the need for the rubber tubeing.
almost finished, all i need to do now is repaint around the sump.
i will be removeing the rubber hose soon and replace it with stainless overbraibed flexi pipe.

so for the sake of only a couple of hours work you could end up saving yourself a few hundred quid.
many thanks to lee at fusion fabrication for the welding at short notice.
hope this is of some use to some of you.
daz

[iceman]

Nice piece of advise as usual from Daz Got to admin ur engine is fookin mint m8. Keep the job up. Ready for show this season?

Cheers

Ben

[M Brian]

do you reckon this might bring back a turbo to life then?

as if this forces oil past the seals - reckon itll mean they aren't duff and they will go back to normal once flow is resumed?


worth a go?


do you have to do something similar for the T3 conversion?

[Project]

Promoted to be a long-standing tuning guide.

More please!

[daz]

melv.
as for the t3 conversion, the turbo sits a little higher up und the flow is almost straight into the block, this coupled with a wider bore tube, leads to zero problems for the t3.
i have placed a t3 union into my block,(now blanked off) incase i wish to go the t3 route at some time.
the oil return on the fiesta block has a thread on it.
hope it is of some help.
daz

[Quantum John]

Daz,
A great post. I have also done this mod on my ZVH. You will experience one slight problem with this mod. It leaks oil.
The oil is at it's hottest and therefore thinest at this point. No matter how much you tighten the bottom jubilee clip you will get a small amount of oil out of it. This is the reason why the standard item is swaged. I enquired about getting mine swaged but unforunately it is not possible because the flexible pipe is not long enough to provide enough flexibility between the angle it comes off the turbo and on to the angle fitting going into the sump. Realistically though, it is such a tiny amount of oil that regular checks will mean no harm to the engine. It's just a pain for those people that like to keep the bottom of their sump nice and shiny!!

There is another factor. While talking to Dave Barker of Puma Racing (a very experience and knowledgeable builder of racing CVH/ZVH engines) there is the theoretical possibility that when thrashing the car round a track (we were at Castle Combe at the time) where extra G forces are experienced going round corners quickly, splashes of oil in the sump could limit the oil getting back into the sump from the turbo. This is probably the reason why Ford designed the return to go back into the block where it would not experience this extreme condition. Ford don't spend millions on car develpment for nothing! However, it should be noted this IS an extreme condition and having a larger diameter return pipe is a great improvement. Obviously, this theoretical condition will not affect cars that are not regularly blasted round a track.

Bit of an essay but points worth considering.

John

[daz]

cheers john for the constructive comments, as you may be able to see from pic 4, i anticipated this hence the reason for inverting the cut t3 pipe, so as the swaged end is at the bottom (pic 6).
granted i may get a little seapage from the bottom one.
as for the oil, my haynes manual states cvh engines hold 3.5 litres, i belive it will be nearer 4.5 0n a turbo, i measured with water , that at 5 litres the water was still below the hole, infact it was coming over the crank recess in the sump pan.
a good idea would for me to add a couple of baffles in there the next time i modify one, the car wont be put on the track however, needless to say someone might if i ever sell it though.
cheers.
might even start offering aturbo saving service now seeing as i have two spare sumps.
thanks once again for your comments
daz

[stusfesta]

ive got a month old T27 hybrid and its started to smoke cos its lettin oil through the seals, could it be my oil return then? ive had it off and cleaned it through and it still smokes wen i start the car up from cold