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Here is a brief explanation of some of the questions you may have. It will be updated when new questions arise.
You undertake these modifications at your own risk, I do not accept any responsibilty for any damage, accident, or expense which arises from following these instructions. If in doubt take it to a proper garage.
What are the biggest size alloys that my standard Mk2 XR2 can take?
You can fit 15" wheels with 195/45R15 tyres, but don't go to wide as the wheels may foul on the arch and suspension strut. If you decide to lower it then there should be no problems but it is not difficult to cut off the arch lip.
It may also be possible to go up to 16's but they would have to be 16"x6" with low profile rubber.
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Can I use unleaded petrol in my XR2?
All fiesta engines before Feb/Mar 1987 do not have hardened valves, so unleaded is a no no unless you use an additive. All engines after March 1987 do have hardened valves so unleaded should be ok, although you will have to adjust the timing.
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My car hesitates badly when I accelerate from low revs, what could be wrong?
It could be an air leak, or the timing could be way off. First check all ht leads and check that the spark plugs are tight.
To find an air leak, first remove the air box and start the car, then gradually black the carb with you hand. The idea behind this is that if there is a leak then the engine should continue running, unless the leak is small or there isn't one in the first place, in which case the engine would stall. Try and listen out for a stucking sound and see if you can feel air being stucked in around the carb and inlet manifold where it joins the head.
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I think my timing is way off and I can't set it correctly.
It could be that the black box on the distributor is worn out. Problems with the distributor are common on XR's and can seriously lower the performance and also shorten the life span of the pistons.
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I want to de-lock my tailgate and remove the rear wiper, but what about the holes?
If you want to do this it is best to get a metal plate welded behind the holes so that the least amount of filling is required. Once welded use a can of Trust P38/40 and spray it over, or you could get a bodyshop to do it for you.
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I need some styling tips for my XR2.
There are loads of styling tips on this site, just click here.
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What is a cam?
The cam is at a basic level, a bar with lobes on it that sits in the cylinder head, it has a pulley attached to one end, and a distributor attached to the other. As the cam turns, the lobes push against tappets (also known as lifters), these tappets lift (hence the other name!) a small bar called a rocker arm (because it rocks like a seesaw!), this bar raises at one end, and pushes down at the other (compressing a spring (valve spring)) this opens a valve inside the cylinder head.
The crank (in the block) has pistons attached to it, on one end of the crank is a pulley (same end as the cam pulley), on the other end is the flywheel.
Between the crank pulley and the cam pulley is a cam belt, this also goes via another pulley which drives the water pump.
Anyway, as the fuel is pumped into the inlet manifold, so is air the cam is designed and positioned in the head so that inlet valve no1 opens, the air and fuel are drawn into the no1 cylinder combustion chamber, at the same time, the cam is timed in conjuction with the crank so that no1 piston is midway between the top and bottom of the no1 cylinder, then as the valve closes, and the piston is compressing the fuel/air, the cam opens the no1 exhaust valve just before the spark plug ignites the fuel, then the exhaust valve lets out the gases into the exhaust manifold, the force from this explosion pushes down the piston, thus turning the crank amd in turn the whole engine! the cycle then continues through cylinders 3, 4, and then 2 in that order.
The ignition timing (when the spark plug ignites the fuel/air) is controlled by the distributor on the side of the cylinder head, once set up, the distributor is driven by the cam to maintain correct timing.
Manufacturers make cams to give good fuel economy and drivability, performance cams have different PROFILES, ie the lobes are slighty different shapes, so that they open the valves at slightly different times/ hold the valves open longer (Known as DURATION) and they can open the valves further (Known as LIFT), this can improve air flow, combustion power at different points in the rev range, therefore giving you more lowdown/midrange/top end power depending on what type of cam you go for.
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What is a flywheel and what happens when it's lightened?
The flywheel is attached to the crank, its primary function is to smooth out the transmission of power from the crank (clutch engages the flywheel -> drives the gearbox -> and turns the driveshafts moving the wheels - bingo!!), this requires weight, however weight can also act as a resistance.
Getting a flywheel lightened and balanced (through machining) can give you a more free reving engine, ie improving the engines response to throttle openings, however this will NOT increase power output. In addition, tuning an engine usually results in a shift of power up the rev range, losing torque at low revs, a lightened flywheel will greatly exagerate this loss of torque at low revs decreasing driveability.
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What does psi stand for?
PSI stands for Pounds per Square Inch, and is a measure of pressure -> ie Force(pounds) divided by Area(square inches).
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What is a strut brace?
A strut brace does almost what it says, it braces the struts. i.e. It is a rigid bar that bolts between the tops of the suspension turrets and reduces the flexing of the parts under heavy cornering. Can make the car handle better due to less body flex.
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What is a swirl pot?
A device in a fuel tank that prevents bubbles getting into the fuel system allowing a constant fuel delivery.
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What is a dump valve?
A device that makes a pleasing noise (or annoying) for turbo'd cars. When running over 18psi of boost (quite a bit) it may help reduce lag and reduce pressure on the propeller shafts.
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What is the maximum speaker mounting depth for the front door speakers?
You can fit 5" diameter speakers with slight modification and you should be able to fit 3" deep speakers with no problems. You may be able to get away with 4" deep speakers depending on the diameter of the magnet.
It is possible to fit 6x9's or 8" speakers in the front doors, to do this read the "How To" Guide.
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What do I need to upgrade to a turbo engine?
You will need to do an RS Turbo conversion first, this will involve converting your car to RS Turbo running gear. When getting an engine make sure you have low compression pistons as you will need these in order to run a turbo.
The Turbo Conversion - By Andy Warren
Bits Needed
Full RS Turbo engine inc. distributor and starter motor, gearbox LSD (optional), turbo on manifold, downpipe from turbo that meets exhaust, injection manifold with vacuum pipe coming off side, turbo air hoses 4 in total 1 small and 3 large, aluminium air in-take pipe (goes across top of engine), fuel meter with red pipes coming from it, Sierra Cosworth fuel pump and filter in cradle, ECU's one black one silver, full RS Turbo wiring loom, 6m of high pressure injection pipe, 1.5m of petrol pipe large diameter to feed fuel pump from tank, a fuel tank with swirl pot fitted (can bought from Fiesta Centre approx. £90), RS Turbo radiator and intercooler.
Fitting
This is a matter of opinion but mine consisted of cutting a small amount from the front crossmember (to allow the exhaust to fit), relocating the battery to the rear, modifying the loom to mate up with that of the XR2's, cutting a fair bit out the front panel to get the radiator and fan in, fabricate and exhaust system, apart from a mount for the fuel distributor that's really all the mods that needs to be done.
Costs
For the engine turbo and gearbox you'll be able to find packages in the paper for between £500 and £1000. Realistically speaking I would lay aside £500-£1000 again to get all the extra's, you can take it down Well Turbo Centre and they'll do it for around £1000.
Other Related Mods
Don't ever forget your brakes and suspension!
BRAKES
It would be best to go with a disc conversion for around £150 this will give you a bracket to allow you to use 285mm disc as apposed to the 240mm as standard thus giving better leverage. If you don't have 15" rims then the next best thing would be to buy some Tarox 6 grove discs nothing else will match these I've tried them and cooked them, pair them up with some fast road Tarox pads and you won't go far wrong.
SUSPENSION
For this at a minimum I'd invest in one of the many sportsline kits where you get 4 uprated shocks and springs for around £200 this should do but I would suggest you invest in uprated or at least new bushes all round, change all your bearings and ball joints and also invest in a strut brace front and rear.
And finally the performance
Standard 135bhp with LSD - 0-60 approx. 7secs - 1/4mile 15.9secs - Max speed - approx 130mph
Modified (mine) with 197bhp and LSD - 0-60 approx. 6.3secs - 1/4mile 14.22secs - Max speed - approx. 140mph
By Andy Warren
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I want to fit rear head rests, how do I do it?
To know how to fit rear head rests read the "How To" guide.
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What does CVH stand for?
It stands for: Compound Valve angle, Hemispherical combustion chamber!
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How do I make a bad boy bonnet?
To make a bad boy bonnet just read the simple "How To" Guide.
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How do I convert to single wiper?
All you need to do is read the "How To" Guide.
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Do you have a question that isn't listed here? If so post a message on the message board
Thanks to Andy Warren, Chris Roderick, Neil, Jason, Ollie and anyone else I forgot to mention!
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