My Millennium

ProjectPuma

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Also these arrived.
A new gear linkage and an Anembo billet gear shifter mount.
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And an omp lower strut brace.
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I had a few hours spare this afternoon so fit the new linkage and mount.
While relatively straightforward and easy to do, getting the two mm bolts out of the plastic housing was a sod of a job. Anyway some scuffed knuckles and a few swear works later I had the housing off.
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The mount was as I'd thought completely shot, the rubber was perished and the plastic insert was only just held in place allowing for a lot of movement.
I removed the 13mm nut from the end of the linkage and after prying the sleeve open a bit it slid straight off.
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The plastic universal joint was seized solid and I was unable to move it by hand, that coupled with the knackered mount explained the stiff yet vague gear change.
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I slid the rubber boot off the old and back onto the new then fit the linkage. Slid the new mount onto the bottom half of the housing and re fit.
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The difference is night and day and feels so much better, smooth and precise.
 
Just a small job this morning, I fit the new idle control valve.
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Now it idles nice and steady and the cold start idle is back.
 
8) getting some great jobs done there which I expect is giving it a new breathe of life
 
OK so the last update was in March, quite a lot has changed since then. I better get this updated.
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Found a picture of my pulsoid location. Surprised I had it on this laptop. Looking in from normal you couldn't see them. Only the white shrouds were a giveaway.

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No idea why I put white round them as I also had black which would have been more stealthy :lol:


EDIT:- I DID!!! - found a later photo :lol: Much better although I think this was when I'd upgraded to the ones like yours as the old ones went doo-lally :lol:

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Simonavis said:
Is that a NOS system I spy in the engine bay? What power have you gone for and how are you finding it works getting the power down
Sorry for the rather late reply, currently jetted for 50bhp. The Michelin ps3 tyres are handling it rather well.
 
The millennium has been off the road since the mot ran out at the end of october, I used the time to sort out the rusty inner arch and generally tidy the car up.
Also since the last update in March, lots of bits have been replaced.
I fit a 2.0 zetec throttle body and bought a cheap inlet manifold that looked far better in the pictures than it did coming out of the box. The previous owner obviously had a fetish for silicone as all the gaskets had it plastered both sides and all around the ports.
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Unfortunately the correct gasket for the throttle body doesn't work with the puma manifold, but was still useful to mark put how much I would need to open the port up.
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Carrying on with replacing various sensors, a new air intake temperature sensor and power steering pressure sensor and new old stock maf.
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An obvious sign ford are starting to cheap out on things, the original brass air intake temperature sensor and the new fiber/plastic one. Ironically the cheaper aftermarket sensors are still brass.
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The oil pressure sensor was an absolute nightmare to remove, it fits into a section of pipe right on a bend with a rubber hose the other side. This makes it almost impossible to get anywhere to grip onto to stop the pipe twisting or bending, and having been there for 22 years certainly didn't help.
 
I replaced the gearbox speed sensor. Its a bit of a fiddly job but made easier with the battery and box removed, also it was only held in by the last couple of threads which would probably explain the random erratic speed reading.
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I also replaced the poly bushed gearbox torque link with a vibratechnics one.
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I found a complete wizards of nos kit on ebay new and unused with the bigger 11lb bottle. As a bonus it had a minimax progressive controller in the box too. This allows nitrous pressure to be built up over a period of seconds instead of the full hit when the pulsoids are activated, meaning more nitrous can be run in a safer way. In all it would have cost nearly £1400 new but managed to get it for £750.
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The updates are copied from my project thread on a focus st forum so sorry if it sounds like you've never seen a puma before.
Due to the way the boot floor is in the puma and from what I've read and been told, the bottle will have to be mounted lengthways instead of behind the rear seat. Id have liked to get ot closer to the side but due to the shape of the boot any further away from the center wouldn't allow the valve to be turned. So it's going to be a slightly less functional boot but at least there's a few cm clearance top and bottom.
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Marked up and pilot holes drilled.
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Holes taken out to 9mm for the rivnuts. The kit actually comes with self tappers to secure the bottle mount but I'm not really a fan of self tappers for securing a fair bit of weight.
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After that I fed the Nitrous feed line behind the rear seat and following the wiring loom along the side of the seat under the carpet and into the engine bay. The only other part I could fit is the nos controller and start some of the wiring. I bent the brackets into the correct shape to allow fitting in the glove box.
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Some more work on the nos install today.
First off I fit the new colder spark plugs, I went for some denso itv16tt iridium plugs.
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Then pulled the injectors to ultrasonic clean them and fit new seals and filters.
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Once the injectors and fuel rail were back on, I fit the schrader valve to 5mm adapter for the fuel supply.
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I tried a few places around the engine bay for fitting the pulsoids without drilling the bodywork.
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Eventually settling with this using a home made bracket. Now I need to finish mocking up the fuel and nitrous lines then finish the wiring.
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I finished feeding the Nitrous supply through into the engine bay and fit the nos pressure gauge.
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I've done a bit more on the puma this afternoon.
I fit the micro switch to the accelerator pedal, although I'm not happy with it (still it works and does the job) so I'll probably buy a throttle position sensor kit that takes the signal from the tps.
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I went for the first trial of the system with the wiring out and power and earth taken directly from the battery through a fused wire.
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A quick video of the pulsoids firing and the minimax controller working. The sound is poor but if you turn up rhe volume you can hear the pulsoids.
[youtube]https://www.youtube.com/watch?v=Ujie5CbMxIg[/youtube]
After the testing I started routing the wiring around the back of the dash and into the engine bay and finding a switched live feed.
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Now I'm just waiting for the wiring loom tape to arrive so I can keep the engine bay looking tidy.
 
I managed to fit my bottle behind the seat with no problems at all (although I notice your brackets are different) so I've no idea why someone said otherwise. I also fitted the pulsoids to holes that were already present under the battery as per the picture I posted previously which made the instal pretty stealthy.
Plus, I like that you put the gauge in the hole on the passenger side - I did exactly the same as it was if it was meant for it, along with putting my controller in the glovebox.
Great minds think alike :thumbs:


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