Post build general maintenance & servicing information to keep the car on the road. i.e. the must do fixes due to wear and tear, breakages or consumables. Larger jobs, or those worth a picture, may have an explicit blog entry.
*Thank you to Marlin Press in California, a fellow Zero builder, for finding and sharing the Dashboard and Engine loom connector part numbers!
Renewals
- Tax: Expired (31/01/2021) SORN
- MOT: Expired (22/10/2020)
- Breakdown cover: 31/05/2024
- Insurance: 31/05/2024 (+ 2k ODO)
Maintenance log:
- 2013 - 176 Miles
- 2014 @ 3.5k Miles - start of season service
- Change oil (3.5k)
- Change coolant/antifreeze (lost on overheat)
- 2015 @ 5.5k Miles - start of season service
- Lubricate Prop-shaft UJs
- Change Timing belt - engine age
- Check plug gaps
- Change oil (2.5k)
- Change oil Filter
- 2015 @ 9k Miles
- Replace flexible fuel lines - originals cracking externally
- Change fuel filter
- 2016 @ 11.8k Miles - start of season service
- Clean air intake filter
- Change coolant/antifreeze (during radiator replacement)
- Differential oil topped up
- 2016 @ 12.8k Miles
- Change oil (7.3k)
- Change oil filter
- Engine Map to adaptive mode
- 2016 @ 15k Miles
- Silencer rattle repair - FOC - Kitspares
- Clocks delaminating decals repair - FOC - Caerbont
- 2017 March @ 16.3k Miles
- Differential oil topped up
- 2017 April @ 18.5k Miles
- Clutch cable adjusted for more throw - crashing on 1st and reverse
- Front indicators replaced - nearside broken lens
- Steering column lower bush replaced - play upper steering column
- Seat nuts and bolts replaced - worn down wear and tear
- Handbrake adjusted
- 2017 May @ 18.8k Miles
- Rear wheel bearings replaced - play in offside
- Spark plugs changed - routine
- All Tyres replaced - wear and tear, esp on rears
- Bonnet chrome (plastic) trim replaced - wear and tear
- 2017 June @ 19.5k Miles
- Clutch cable replaced - pedal end flange broken
- Change Oil (6.7k) and Oil filter
- IACV Air filter changed
- 2017 Aug @ 20.1k Miles
- Lubricate Prop-shaft UJs
- Diff oil top up
- 2018 June @ 24k Miles
- Brake fluid change
- Front shocks replaced
- 2019 April @ 25.5k Miles
- Change Oil (6k) and Oil filter
- Clean out oil pump sump pickup grille
- Replace sump washers with dowty washers
- Lubricate Prop-shaft UJs
- Check and top up diff oil
- 2020 January @ 28.5k Miles
- Replace water temp sensor & radiator thermostat 88ÂșC
- Replace number plate lamp
- 2020 May @ 28.5k Miles
- Replace head gasket
- 16PSI coolant cap
- 2020 October @ 28.5k Miles
- Top up diff oil
- Adjust handbrake cable
- 2021 May @ 28,619
- Change Oil (3.1k)
- Top up diff oil
- 2021 Dec @ 28,619
- New Seats - Vinyl going home on the originals
- Replace Battery (not holding a charge anymore)
Parts reference:
Log of parts used on the Zero, OEM, upgrades, future reference.
Yellow = not certain/not necessarily tried myself yet
Yellow = not certain/not necessarily tried myself yet
Interior
- Seat mounting holes ~12" left/right, fore/aft
Lights
- Headlamps: H4 - Philips X-treme vision
- Tail lights: P21/5
- Tail indicators: PY21W
- Front indicators: 23W BA9S
Brakes
- Front pads: Mintex MDB1175M1144, (Ferrodo DS2500 FCP206H)
- Front discs: BM002 240x24mm, Offset 58, Bore 64, PCD 108 (e.g. RallyDesign)
- Rear pads: Mintex MDB12871144, (Ferrodo DS2500 FCP408H)
- Rear discs: 257x22mm PCD 108 (Sierra XR4 Rear disc?)
- Fluid: DOT4 ~0.5L
Engine
- Engine build: 17/08/2004, Zetec E Black top (Phase 3)
- Diff Oil: SAE 75W90 EP GL5 Gear Oil
- Engine Oil: 5w30 Semi-synthetic, ~5 litres
- Gearbox Oil: 75W90 Semi-synthetic GL4
- Engine coolant: ~4.5 litres
- Raceline sump plug washer: 21mm ID, 27mm OD, 1mm thick or 3/4" & 1/2" BSP dowty
- Oil Filter: Fujitoyo FO-9217 or Trupart FO9217 or LS934 - O/D:80mm, Thread: 3/4x16UNF, H:79mm, Anti drain, PRV: 13-16
- Fuel Filter: Sytec 8mm/8mm SSF2070 (Larger than OEM filter)
- Spark Plugs: NGK Platinum NGKPTR5A-10
- Spark Plug Gap: 1.0mm
- Timing belt/Kit: SKF VKMA 04214
- Rocker cover gasket: search for Ford Focus, Mondeo 2.0 Gasket kit: RC8328
- Alternator/Water Aux pump Belt: DAYCO 5PK 1100 - 5 rib, 1100mm
- Alternator: Nippon Denso A073 5v 40A: 103 400354, 02 512-206(Kubuta A2198 60A?, LEA100-88LW 60A?)
- Radiator (not GBS/OEM): VW Polo 1983-1990 380x323mm core (e.g. Ebay)
- Radiator cap: OBP PC003 (16psi) was OBP PC004 (20psi)
- Lambda Sensor Wideband: Bosch LSU 4.9 - 17025 0-258-017-025 -4UG
- Starter Motor: LRS707 (unconfirmed)
- LP Fuel Pump: Facet 40105k 3-4.5psi 1/8"npt 30USg/hr ?60106 backup? FUE0023?
- HP Fuel Pump: Sytec HI P3017.1 OTP017 12mm / 8mm push on (spare) (Bosch 044?) FUE0011
- Injectors: Bosch 0-280-155-820 18.25Lb/Hr 191.8cc/min 138g 43.5PSI 3Bar
- IACV: Normal operation : 7-13 Ohms
- Clutch Cable (OEM routed inside engine mount) 92cm/73cm
- Thermostat 54mm diameter, 22.5mm bottom, 17.8mm top 88ÂșC: (QT100K 82Âș, QT101K 74Âș QT102K 88Âș QT107K 92Âș) QT102K fitted
- Radiator backup thermostat switch: M22x1.5 98-93ÂșC FAE 37400
- Coolant sensor (ECU) E450
- Battery type '063' 40Ah 340CCA (175mm x175mm x207mm)
- Clutch plate: 'com934 3n' clutch kit 23 tooth spline, 240mm (may be MT75 specific - check)
Suspension and Wheels
- Weight with driver: 760kg, distribution front: 340kg, rear: 420kg
- Tyre pressure: 20psi (was 18, trying a little higher to even tyre wear)
- Steering Rack: Escort Mk2 - 260mm mounting centres, 1095mm total length, M14 threads, 2.4 quick rack
- Track rod ends: Sierra: Ball joint:M10x1mm fine
- Wheels: 7Jx15" 4x108 ET15
- Tyres: 195/50 R15 82V: Current: Hankook Ventus V12 evo2(K120), Yokohama Parada (18.8k 4years - spare)
- Wheel nuts: M12x1.5 (Spare/boot rods M12x1.25)
- Front wishbone bottom ball joint: Astra Mk3 (Delphi Lockheed part TC397)
- Front wishbone top ball joint: Ford Transit track rod end FTR4700
- Rear wheel bearings: Sierra 2WD - OD: 60mm ID: 35mm width 19mm BRT990
- Suspension arm bushes: Powerflex PF99-113P, PF99-113 (TBC) Kitspares SUS0033
- Shocks/Springs: Protech
- Front shocks: 1.9" ID spring seats, 14" open length, bushes M12 - T:25mm, B:20mm
- Rear shocks: 1.9" ID spring seats, (Ford)12"
- Front springs: 9" 350lbs 1.9" ID
- Rear springs: 8" 275lbs 1.9" ID, (originals were 8" x 250)
- Geometry:
- Shocks front: Protech +2 clicks (Clockwise = harder)
- Shocks rear: Gaz +9 clicks (was 5, 10, 7)
- Chassis to ground: Rear 130mm, Front 120mm (Factory uses 120,110)
- Front: 0Âș04' toe-in each side, -1.3Âș camber
- Rear: not adjustable (Needs Shims) - target 0Âș29' toe in, -1.3Âș camber
Loom Connectors and Components
Useful for adding new circuits on spare pins.
- Narrowband Lambda 4 pin Socket: Deutsch DTM
- 6.3mm blade connectors: Durite (Interparts)
- 2 way T: 0-011-13, 0-011-03
- 4 way: 0-011-15, 0-011-05
- 11 way: 0-011-18, 0-011-08
- Female terminal: 0-011-023 <1mm² -24 >1mm²
- Male terminal: 0-011-021 <1mm² -22 >1mm²
Mouser part numbers
- Fuse Box
- Dashboard / clocks 20 pin connector* (.070 Multilock)
- Plug #571-174952-1
- Socket #571-174936-1
- Male Pin #571-173633-2
- Female Pin #571-173630-6
- Engine Loom 12 pin connector*
- Plug #571-DTM04-12PA, Wedge lock #571-WM-12P
- Socket #571-DTM06-12SA, Wedge lock #571-WM-12S
- Female pin #571-0462-201-20141
- Male pin #571-0460-202-20141
*Thank you to Marlin Press in California, a fellow Zero builder, for finding and sharing the Dashboard and Engine loom connector part numbers!
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