2.0 Zetec into 1.6 Si - full conversion guide.
123 posts • Page 1 of 4 • 1, 2, 3, 4
2.0 Zetec into 1.6 Si - full conversion guide.
by AdrianFRST on Fri Sep 26, 2003 10:34 am
Many thanks to Paul Baker for writing this guide.
Primary Considerations
PATS
No nothing to do with a certain East Enders character but the acronym used by Ford for their internal anti-theft system. It actually stands for Passive Anti-Theft System and as been around on Fords since the early nineties. There have been a number of generations of PATS ranging from the fairly simple early systems to todays systems that are linked with the Engine Management system. The basic principle of all of the systems is that there is a chip, you’ll notice a litle red tab on a Ford key which is the chip, and I thought it was just to make the key look pretty, that talks to a de-coder which surrounds the ignition switch which in turn talks to the PATS module and on later cars the ECU. When you put the key in the ignition, the signal is checked by the PATS unit to ensure it is compatible and if so the PATS module enables the main circuits to the ECU and to the Fuel Pump thus enabling the car to be started. On later PATS systems these are more sophisiticated and the PATS module also talks to the ECU and enables the fuel circuits in the ECU as opposed to external to it. For the unitiated the PATS system will often be referred to as internal or external dependant if the PATS system is integrated with the ECU or not.
A quick call to a local company quickly confirmed that my Fiesta Si was equipped with external PATS which was good news on two counts, one that I could retain the security and two that I would not need to worry about PATS when changing the ECU, so good news all round really. If any readers want a real laugh try asking anyone in Ford about PATS, you’d think you’d asked for Bin Laden’s phone number the whole area is considered, probably quite rightly, as highly sensitive. If you take the trouble to look at the PATS wiring you’ll quickly notice that all the wires are brown, also for security reasons!!!!!
EDIS
EDIS can be managed seperately from the ECU via an EDIS module or can be managed within the ECU. All ’93-’97 Mondeos, with the exception of the Automatic, had internal EDIS whilst I beleives that all earlier Zetec Fiestas like XR2i and RS1800 had a seperate EDIS module. Because of this I assumed I would need to do a certain amount of re-wiring to support the Mondeo ECU. However I discovered to my joy that the 1.6Si Fiesta had internal EDIS the same as the Mondeo so in theory I would not need to make any loom changes assuming that the pin connections were the same between the Fiesta ECU and the Mondeo ECU. I set out to try to confirm this but in the process managed to find a contact on the FiestaTurbo.com forum who had done the same 1.6 to 2.0 conversion and had established that the ECUs could just be swapped.
Mechanical Considerations
Apart from the engine management considerations there are a number of mechanical changes that need to be done to get the 2.0 Mondeo engine in to a Fiesta or a Quantum H4. specifically these are as follows, for a more detailed description of the modifications required take a look at Mark Stewart’s excellent web site and at Jim Hearne’s equally useful site
[EDIT] - fiestaprojects.com is no longer online.
http://www.jimhearne.co.uk
Sump
The Mondeo sump has the step in the wrong place and would foul the Fiesta Exhaust Manifold, solution is a straight swap for the Fiesta Sump. Whilst you are at it you also need to swap over the oil pick up pipe as well.
Exhaust Manifold
Does not line up with the Fiesta Exhaust position, solution is a straight swap. It turns out that the manifold port sizes are the same on the 1.6/1.8 and 2.0 Zetec engines.
Water Pump
The Mondeo water pump is driven by the flat side of the belt and rotates in the opposite direction to the Fiesta so this is also a straight swap for the Fiesta pump and the Fiesat pump pulley
Alternator
The Mondeo alternator is mounted at the rear of the engine and basically just won’t fit, the solution again is to use the Fiesat alternator and mounting bracket etc
Power Steering Pump
The pump appears to be the same on the Fiesta and Mondeo but is mounted completely differently due to the differences in the drive belt arrangement between the Mondeo and the Fiesta so I used the Fiesta pump and bracketry. You need to use the bracketry anyway because of the alternator swap.
Inlet Manifold
The Mondeo inlet manifold curves back down and basically just won’t fit in the Fiesta engine bay. The solution is to use the Fiesta inlet manifold so it will all fit in. One issue here is that the 1.6 inlet manifold is smaller than the Mondeo one and also the manifold ports are smaller than the 2.0 inlet ports which results in a step change out where the manifold meets the head. Some others who have done this conversion have smoothed out the transition by filing out the inlet manifold, however you are still stuck with the overall smaller manifold bore. I spoke to Dave Baker at Puma Racing who reckoned that the effort of smoothing out this transition was just not worth it as overall flow will be dictated by the manifold size and the step up where it meets the head will not have a marked effect on performance. What is not known is what effect the smaller manfold size has on performance but unless you felt like fabricating a custom manifold then there is really no choice in the matter. I reckoned that this manifold will happily flow 130BHP on the RS1800 engine so the effect may not be massive, unless I get the car on a rolling road I’ll probably never know. If anyone wants to offer me a free power run on a local rolling road I wouldn’t turn them down.
Throttle Body
The 1.6 Throttle body is way too small so you have to use the Mondeo throttle body which happily bolts on to the 1.6 inlet manifold. You do however have to swap over the throttle linkage and the cable retaining plate from the Fiesta Throttle Body. I was told this is a straight swap but in my case this was only partially true as I found I had to cut/file lumps off the cable retaining plate and also found I had to file out the main throttle linkage bore as the Fiesta one is too small for the Mondeo spigot. I think I could just have swapped the spigots over but just could not undo them.
Dipstick Tube
You also need to use the Fiesta dipstick tube as the Mondeo one would foul the Fiesta exhaust manifold.
Engine Mounts
If, like me, you already have a 1.6 Zetec in the car then you can just use the Fiesta mounts as they are. If you have a CVH then you will need to mod the engine mounts I believe as discussed on the web sites previously referred to.
Oil Pump
Those who have done this conversion in a Fiesta will know that you have to also change the oil pump because on the Fiesta it angles in to clear the chassis.
Flywheel
The Mondeo engine I bought was an automatic and as such came with no flywheel so I used the 1.6 flywheel. I believe that even if you use a Mondeo manual engine you still have to swap the flywheel as the Mondeo one is too large for the BC gearbox which was already fitted to the car
Starter Motor
The Mondeo starter motor is fitted to the rear of the engine whereas on the Fiesta engine it’s at the front which means you have to use the Fiesta one but it just bolts straight on. The only downside is you are left with a small gap at the rear of the engine where it meets the gearbox and one less gearbox mounting bolt. The lack of one bolt I don’t reckon will be a problem and I made up a blanking plate to cover the resulting gap.
Injectors
I used the beige Mondeo injectors as opposed to the black Fiesta ones but retained the Fiesta fuel rail and Pressure relief valve, they are the same on the Mondeo anyway
Sensors etc
All the sensors are pretty well interchangeable as far as I could tell with the exception of the obvious one which is the Mass Air Flow Sensor that is a significantly larger diameter than the 1.6 unit, however this is a straight swap for the Fiesta one. I also used the Mondeo idle stepper motor and also retained all of the Mondeo engine sensors.
The big one to watch out for that I missed is the Crank Angle Sensor which is fixed to an alloy housing which is bolted to the rear of the block. Because I used a Mondeo Automatic the sensor is fixed at a larger diameter than the sensor holes in the 1.6 flywheel I used. I didn’t realise this until I came to start the engine and had no spark or fuel. The solution was to change this alloy housing to correctly re-position the sensor. The bad news was that I had to remove the gearbox again to change this!!!!!
Crank Angle Sensor Mounting Block—Beware!!!
So was it all easy and was it all worth it???
Undoubtedly yes, the whole conversion took around 4 days in total and I reckon a mechanic used to dealing with Fiestas could have the job done in 3 days. The difference in performance is significant as you would expect having gone from 85BHP to somewhere nearer 130BHP along with the associated ramp up in Torque.
Using the 1.6Si gearbox means that the car tops out at around 125mph , I have been told that by using the RS1800 box I could expect to see 140 mph at the top end but personally I am happier having the better acceleration offered by the Si gearbox as opposed to a higher top speed. I have also found that the Torque on tap means that 1st gear has become nearly redundant and that the car pulls really strongly in all the gears.
So what did it all cost & was it worth it??
Not too bad really given the fact that I already had a 1.6 Zetec engine to start with, for anyone who already has a 1.6 Zetec engined car the it’s a no brainer. If you do not already have a 1.6 Zetec then sourcing all the zetec bits you need could be difficult but if you could find a complete say siezed engine or the like cheap then it would not be so prohibitive.
My Mondeo engine cost me £460 and the manual ECU I picked up out of Loot for £25 which was a bit of a bargain. In addition to these there were the usual collection of Gaskets, Oil and Filter, Antifreeze, Plugs and it’s surprising how these add up. I also hired an engine hoist for two separate days. So all in all I reckon the conversion cost me around £600 in total which the way I look at it for an increase of 45BHP ie 53% over the 1.6 Zetec is a bit of a bargain when compared to say a Weber Alpha Carb or Throttle Body and engine management conversion which would have only got me to around 125BHP and would have cost roughly twice as much.
Primary Considerations
PATS
No nothing to do with a certain East Enders character but the acronym used by Ford for their internal anti-theft system. It actually stands for Passive Anti-Theft System and as been around on Fords since the early nineties. There have been a number of generations of PATS ranging from the fairly simple early systems to todays systems that are linked with the Engine Management system. The basic principle of all of the systems is that there is a chip, you’ll notice a litle red tab on a Ford key which is the chip, and I thought it was just to make the key look pretty, that talks to a de-coder which surrounds the ignition switch which in turn talks to the PATS module and on later cars the ECU. When you put the key in the ignition, the signal is checked by the PATS unit to ensure it is compatible and if so the PATS module enables the main circuits to the ECU and to the Fuel Pump thus enabling the car to be started. On later PATS systems these are more sophisiticated and the PATS module also talks to the ECU and enables the fuel circuits in the ECU as opposed to external to it. For the unitiated the PATS system will often be referred to as internal or external dependant if the PATS system is integrated with the ECU or not.
A quick call to a local company quickly confirmed that my Fiesta Si was equipped with external PATS which was good news on two counts, one that I could retain the security and two that I would not need to worry about PATS when changing the ECU, so good news all round really. If any readers want a real laugh try asking anyone in Ford about PATS, you’d think you’d asked for Bin Laden’s phone number the whole area is considered, probably quite rightly, as highly sensitive. If you take the trouble to look at the PATS wiring you’ll quickly notice that all the wires are brown, also for security reasons!!!!!
EDIS
EDIS can be managed seperately from the ECU via an EDIS module or can be managed within the ECU. All ’93-’97 Mondeos, with the exception of the Automatic, had internal EDIS whilst I beleives that all earlier Zetec Fiestas like XR2i and RS1800 had a seperate EDIS module. Because of this I assumed I would need to do a certain amount of re-wiring to support the Mondeo ECU. However I discovered to my joy that the 1.6Si Fiesta had internal EDIS the same as the Mondeo so in theory I would not need to make any loom changes assuming that the pin connections were the same between the Fiesta ECU and the Mondeo ECU. I set out to try to confirm this but in the process managed to find a contact on the FiestaTurbo.com forum who had done the same 1.6 to 2.0 conversion and had established that the ECUs could just be swapped.
Mechanical Considerations
Apart from the engine management considerations there are a number of mechanical changes that need to be done to get the 2.0 Mondeo engine in to a Fiesta or a Quantum H4. specifically these are as follows, for a more detailed description of the modifications required take a look at Mark Stewart’s excellent web site and at Jim Hearne’s equally useful site
[EDIT] - fiestaprojects.com is no longer online.
http://www.jimhearne.co.uk
Sump
The Mondeo sump has the step in the wrong place and would foul the Fiesta Exhaust Manifold, solution is a straight swap for the Fiesta Sump. Whilst you are at it you also need to swap over the oil pick up pipe as well.
Exhaust Manifold
Does not line up with the Fiesta Exhaust position, solution is a straight swap. It turns out that the manifold port sizes are the same on the 1.6/1.8 and 2.0 Zetec engines.
Water Pump
The Mondeo water pump is driven by the flat side of the belt and rotates in the opposite direction to the Fiesta so this is also a straight swap for the Fiesta pump and the Fiesat pump pulley
Alternator
The Mondeo alternator is mounted at the rear of the engine and basically just won’t fit, the solution again is to use the Fiesat alternator and mounting bracket etc
Power Steering Pump
The pump appears to be the same on the Fiesta and Mondeo but is mounted completely differently due to the differences in the drive belt arrangement between the Mondeo and the Fiesta so I used the Fiesta pump and bracketry. You need to use the bracketry anyway because of the alternator swap.
Inlet Manifold
The Mondeo inlet manifold curves back down and basically just won’t fit in the Fiesta engine bay. The solution is to use the Fiesta inlet manifold so it will all fit in. One issue here is that the 1.6 inlet manifold is smaller than the Mondeo one and also the manifold ports are smaller than the 2.0 inlet ports which results in a step change out where the manifold meets the head. Some others who have done this conversion have smoothed out the transition by filing out the inlet manifold, however you are still stuck with the overall smaller manifold bore. I spoke to Dave Baker at Puma Racing who reckoned that the effort of smoothing out this transition was just not worth it as overall flow will be dictated by the manifold size and the step up where it meets the head will not have a marked effect on performance. What is not known is what effect the smaller manfold size has on performance but unless you felt like fabricating a custom manifold then there is really no choice in the matter. I reckoned that this manifold will happily flow 130BHP on the RS1800 engine so the effect may not be massive, unless I get the car on a rolling road I’ll probably never know. If anyone wants to offer me a free power run on a local rolling road I wouldn’t turn them down.
Throttle Body
The 1.6 Throttle body is way too small so you have to use the Mondeo throttle body which happily bolts on to the 1.6 inlet manifold. You do however have to swap over the throttle linkage and the cable retaining plate from the Fiesta Throttle Body. I was told this is a straight swap but in my case this was only partially true as I found I had to cut/file lumps off the cable retaining plate and also found I had to file out the main throttle linkage bore as the Fiesta one is too small for the Mondeo spigot. I think I could just have swapped the spigots over but just could not undo them.
Dipstick Tube
You also need to use the Fiesta dipstick tube as the Mondeo one would foul the Fiesta exhaust manifold.
Engine Mounts
If, like me, you already have a 1.6 Zetec in the car then you can just use the Fiesta mounts as they are. If you have a CVH then you will need to mod the engine mounts I believe as discussed on the web sites previously referred to.
Oil Pump
Those who have done this conversion in a Fiesta will know that you have to also change the oil pump because on the Fiesta it angles in to clear the chassis.
Flywheel
The Mondeo engine I bought was an automatic and as such came with no flywheel so I used the 1.6 flywheel. I believe that even if you use a Mondeo manual engine you still have to swap the flywheel as the Mondeo one is too large for the BC gearbox which was already fitted to the car
Starter Motor
The Mondeo starter motor is fitted to the rear of the engine whereas on the Fiesta engine it’s at the front which means you have to use the Fiesta one but it just bolts straight on. The only downside is you are left with a small gap at the rear of the engine where it meets the gearbox and one less gearbox mounting bolt. The lack of one bolt I don’t reckon will be a problem and I made up a blanking plate to cover the resulting gap.
Injectors
I used the beige Mondeo injectors as opposed to the black Fiesta ones but retained the Fiesta fuel rail and Pressure relief valve, they are the same on the Mondeo anyway
Sensors etc
All the sensors are pretty well interchangeable as far as I could tell with the exception of the obvious one which is the Mass Air Flow Sensor that is a significantly larger diameter than the 1.6 unit, however this is a straight swap for the Fiesta one. I also used the Mondeo idle stepper motor and also retained all of the Mondeo engine sensors.
The big one to watch out for that I missed is the Crank Angle Sensor which is fixed to an alloy housing which is bolted to the rear of the block. Because I used a Mondeo Automatic the sensor is fixed at a larger diameter than the sensor holes in the 1.6 flywheel I used. I didn’t realise this until I came to start the engine and had no spark or fuel. The solution was to change this alloy housing to correctly re-position the sensor. The bad news was that I had to remove the gearbox again to change this!!!!!
Crank Angle Sensor Mounting Block—Beware!!!
So was it all easy and was it all worth it???
Undoubtedly yes, the whole conversion took around 4 days in total and I reckon a mechanic used to dealing with Fiestas could have the job done in 3 days. The difference in performance is significant as you would expect having gone from 85BHP to somewhere nearer 130BHP along with the associated ramp up in Torque.
Using the 1.6Si gearbox means that the car tops out at around 125mph , I have been told that by using the RS1800 box I could expect to see 140 mph at the top end but personally I am happier having the better acceleration offered by the Si gearbox as opposed to a higher top speed. I have also found that the Torque on tap means that 1st gear has become nearly redundant and that the car pulls really strongly in all the gears.
So what did it all cost & was it worth it??
Not too bad really given the fact that I already had a 1.6 Zetec engine to start with, for anyone who already has a 1.6 Zetec engined car the it’s a no brainer. If you do not already have a 1.6 Zetec then sourcing all the zetec bits you need could be difficult but if you could find a complete say siezed engine or the like cheap then it would not be so prohibitive.
My Mondeo engine cost me £460 and the manual ECU I picked up out of Loot for £25 which was a bit of a bargain. In addition to these there were the usual collection of Gaskets, Oil and Filter, Antifreeze, Plugs and it’s surprising how these add up. I also hired an engine hoist for two separate days. So all in all I reckon the conversion cost me around £600 in total which the way I look at it for an increase of 45BHP ie 53% over the 1.6 Zetec is a bit of a bargain when compared to say a Weber Alpha Carb or Throttle Body and engine management conversion which would have only got me to around 125BHP and would have cost roughly twice as much.
- AdrianFRST
- Baby Battle Scratch
- Posts: 7381
- Joined: Sat Sep 25, 1999 12:00 am
- Location: A long walk, and it's that-a-way...
- Your car: ..? Pretty car..!
Car: 2010 Ford Focus RS
by Fiestasi-Andy on Fri Sep 26, 2003 11:12 am
what a great post, this will be viewed by myself & i'm sure other people lots & lots of times 
My Bad!
Sorry
Sorry
- Fiestasi-Andy
- Elite Post Master
- Posts: 4754
- Joined: Thu Mar 21, 2002 12:00 am
- Location: .........
by SantaHul on Wed Oct 01, 2003 3:36 am
After you've done all this, what kind of figures can you expect?
0-60? Top speed?
0-60? Top speed?
Tip of the month: Don't put your new iPod Nano in the washing machine 
Been gone for 6 months, did anybody even notice?
Been gone for 6 months, did anybody even notice?
- SantaHul
- Elite Post Master
- Posts: 1317
- Joined: Thu Mar 06, 2003 8:13 pm
- Location: The top of the food chain (and Derby) Drives: Fiesta Si 16v & Mini Cooper
by AdrianFRST on Wed Oct 01, 2003 8:40 am
SantaHul :After you've done all this, what kind of figures can you expect?
0-60? Top speed?
How much do you weigh?
Also, what wheels and tyres are on the car? - size, rotational velocity mass, and what are the gear ratios and final drive?
They'll affect the figures so it's not really possible to say without knowing them.
- AdrianFRST
- Baby Battle Scratch
- Posts: 7381
- Joined: Sat Sep 25, 1999 12:00 am
- Location: A long walk, and it's that-a-way...
- Your car: ..? Pretty car..!
Car: 2010 Ford Focus RS
by paulbaker on Wed Oct 01, 2003 1:34 pm
SantaHul :After you've done all this, what kind of figures can you expect?
0-60? Top speed?
Adrian is right but FYI i have 15" TSW's with 195/65 tyres and the standard Si box. I reckon 0-60 is around the 6-7s mark though I have not accurately measured it and top speed is around 125 with this combination. One thing I would like to have is a lower ratio on the top gear as the car revs too highly at around 90. This woud also up the Top Speed slightly
IT WAS A FIESTA--UNTIL--THE ULTIMATE FEZ BODY KIT!!!
QUANTUM H4--2.0 ZETEC POWER--ALL I WANT FOR CHRISTMAS IS A NOS KIT
QUANTUM H4--2.0 ZETEC POWER--ALL I WANT FOR CHRISTMAS IS A NOS KIT
- paulbaker
- Poster
- Posts: 108
- Joined: Thu Jun 13, 2002 9:30 am
- Location: Warrington
by AsianGunner on Sat Oct 18, 2003 1:20 pm
brilliant post mate! 
My name is Nick and i'm addicted to Cars, Women and Arsenal!!...not in that order..lol
- AsianGunner
- Senior Poster
- Posts: 431
- Joined: Wed Jul 09, 2003 4:12 pm
- Location: s.e London
by mental youth on Mon Oct 27, 2003 3:08 pm
TT motorsport reckon about a grand for the work alone you said it cost you 600 quid to do yourself
why not start nockin a full conversion out at grand a time or more i know i would have it done!!!
400 quid for 4 days work that cant be bad
why not start nockin a full conversion out at grand a time or more i know i would have it done!!!
400 quid for 4 days work that cant be bad
i'm no boy racer just bad look. . . honest!
- mental youth
- Poster
- Posts: 122
- Joined: Tue Feb 18, 2003 5:10 pm
- Location: birmingham
by JamieFRST on Mon Nov 03, 2003 7:27 pm
Very well written, still thinking of putting a 2L in my 2i, but not sure its really worth it, although i like my car and want more power, i think a fiesta turbo is the way to go 
- JamieFRST
- Keep It Tidy
- Posts: 23917
- Joined: Tue May 01, 2001 1:00 am
Car: 1991 Ford Fiesta RS Turbo
by AndyRS1800 on Mon Nov 10, 2003 6:37 pm
I have a 1.8 zetec in mine, looks like i have a good base to fit a 2.0 as i have the fiesta zetec parts but also the bigger inlet and stuff...
Sounds a good idia, think i'll have to get this done as i feel the need to go for a 2.0 just for the sake of it really,
Nice 1...
Sounds a good idia, think i'll have to get this done as i feel the need to go for a 2.0 just for the sake of it really,
Nice 1...
- AndyRS1800
- Elite Post Master
- Posts: 5239
- Joined: Sun Aug 19, 2001 1:00 am
- Location: Bolton.... Drives: Golf GTi Turbo for now
by SantaHul on Thu Nov 13, 2003 5:49 am
paulbaker :I reckon 0-60 is around the 6-7s mark
that'll do, i was only after a vague idea cheers paul
can it be a series 1 or 2 zetec or does it have to be a series 1 like the si already has in. i'd really like a series 2.
Tip of the month: Don't put your new iPod Nano in the washing machine
Been gone for 6 months, did anybody even notice?
Been gone for 6 months, did anybody even notice?
- SantaHul
- Elite Post Master
- Posts: 1317
- Joined: Thu Mar 06, 2003 8:13 pm
- Location: The top of the food chain (and Derby) Drives: Fiesta Si 16v & Mini Cooper
by Swanick on Thu Nov 13, 2003 6:45 am
paulbaker :SantaHul :After you've done all this, what kind of figures can you expect?
0-60? Top speed?
Adrian is right but FYI i have 15" TSW's with 195/65 tyres and the standard Si box. I reckon 0-60 is around the 6-7s mark though I have not accurately measured it and top speed is around 125 with this combination. One thing I would like to have is a lower ratio on the top gear as the car revs too highly at around 90. This woud also up the Top Speed slightly
what does your car weigh? and waht would a standard fiesta weigh?
- Swanick
- Escort RS Turbo
- Posts: 12166
- Joined: Tue May 07, 2002 11:29 pm
- Location: Denbigh
by paulbaker on Fri Nov 14, 2003 9:40 am
Swanick :paulbaker :SantaHul :After you've done all this, what kind of figures can you expect?
0-60? Top speed?
Adrian is right but FYI i have 15" TSW's with 195/65 tyres and the standard Si box. I reckon 0-60 is around the 6-7s mark though I have not accurately measured it and top speed is around 125 with this combination. One thing I would like to have is a lower ratio on the top gear as the car revs too highly at around 90. This woud also up the Top Speed slightly
what does your car weigh? and waht would a standard fiesta weigh?
I also agree if anyone happens to now what box would help this, ie similar ratios 1-4 but a lower ratio (or is it higher??) to give a higher top speed along with lower cruising revs would be nice to know.
IT WAS A FIESTA--UNTIL--THE ULTIMATE FEZ BODY KIT!!!
QUANTUM H4--2.0 ZETEC POWER--ALL I WANT FOR CHRISTMAS IS A NOS KIT
QUANTUM H4--2.0 ZETEC POWER--ALL I WANT FOR CHRISTMAS IS A NOS KIT
- paulbaker
- Poster
- Posts: 108
- Joined: Thu Jun 13, 2002 9:30 am
- Location: Warrington
by MaXsteri on Sun Nov 16, 2003 9:15 am
SantaHul :Can it be a series 1 or 2 zetec or does it have to be a series 1 like the si already has in
Doesnt matter, either or.
FYI the later SI's have Series 2's. All good
- MaXsteri
- Elite Post Master
- Posts: 4485
- Joined: Wed Jul 17, 2002 7:15 pm
- Location: Eastbourne
by SantaHul on Sun Nov 16, 2003 12:48 pm
MaXsteri :FYI the later SI's have Series 2's. All good
they do?
sh!t, i woulda looked out for one of them if i'd known
Tip of the month: Don't put your new iPod Nano in the washing machine
Been gone for 6 months, did anybody even notice?
Been gone for 6 months, did anybody even notice?
- SantaHul
- Elite Post Master
- Posts: 1317
- Joined: Thu Mar 06, 2003 8:13 pm
- Location: The top of the food chain (and Derby) Drives: Fiesta Si 16v & Mini Cooper
by SantaHul on Sun Nov 16, 2003 5:08 pm
MaXsteri :Why? makes no difference when your gonna replace the engine anyway
...as long as i can find the money, and it wont be for ages either
anywayz, wasnt planning on changing the engine when i bought it
Tip of the month: Don't put your new iPod Nano in the washing machine
Been gone for 6 months, did anybody even notice?
Been gone for 6 months, did anybody even notice?
- SantaHul
- Elite Post Master
- Posts: 1317
- Joined: Thu Mar 06, 2003 8:13 pm
- Location: The top of the food chain (and Derby) Drives: Fiesta Si 16v & Mini Cooper
by Maff Si on Sun Nov 23, 2003 9:15 pm
Quite a lot more work involved
Engine mount holes need re-drilling, you will need a new loom or your existing one will need patching, rad and exhaust will need replacing too plus other stuff
Take a look at Al's Engine swap page
Engine mount holes need re-drilling, you will need a new loom or your existing one will need patching, rad and exhaust will need replacing too plus other stuff
Take a look at Al's Engine swap page
No Filler Nova Killer - Goes Like A Bomb
When I'm not here I'm somewhere else
When I'm not here I'm somewhere else
- Maff Si
- Elite Post Master
- Posts: 1342
- Joined: Sat Sep 22, 2001 1:00 am
- Location: East SusSEX Drives:'94 1.6 16v Si
- Your car: Nothing til end of the month
by paulbaker on Tue Dec 02, 2003 9:42 am
mattssi :Wot sort of price would u be lookin at at to turbo a 2ltr ?
Looked at this myself reckon that as a min you are looking at around 3 Grand minimum
IT WAS A FIESTA--UNTIL--THE ULTIMATE FEZ BODY KIT!!!
QUANTUM H4--2.0 ZETEC POWER--ALL I WANT FOR CHRISTMAS IS A NOS KIT
QUANTUM H4--2.0 ZETEC POWER--ALL I WANT FOR CHRISTMAS IS A NOS KIT
- paulbaker
- Poster
- Posts: 108
- Joined: Thu Jun 13, 2002 9:30 am
- Location: Warrington
by dodger522 on Sun Dec 21, 2003 11:59 pm
wikid post think i will have 2 add this conversion 2 the "i need this much$$$ 4 my car" as i still cant find a desent 3 door 1.6si ther all 1.4 4doors 
u got knocked the f**k out!!!!!!!!!
- dodger522
- Poster
- Posts: 174
- Joined: Mon Dec 15, 2003 10:39 pm
- Location: bristol
by dodger522 on Sun Dec 21, 2003 11:59 pm
wikid post think i will have 2 add this conversion 2 the "i need this much$$$ 4 my car" as i still cant find a desent 3 door 1.6si ther all 1.4 4doors
u got knocked the f**k out!!!!!!!!!
- dodger522
- Poster
- Posts: 174
- Joined: Mon Dec 15, 2003 10:39 pm
- Location: bristol
by dodger522 on Sun Dec 21, 2003 11:59 pm
wikid post think i will have 2 add this conversion 2 the "i need this much$$$ 4 my car" as i still cant find a desent 3 door 1.6si ther all 1.4 4doors
u got knocked the f**k out!!!!!!!!!
- dodger522
- Poster
- Posts: 174
- Joined: Mon Dec 15, 2003 10:39 pm
- Location: bristol
by StreetDragster on Sun Apr 11, 2004 11:01 pm
Throttle Body
The 1.6 Throttle body is way too small so you have to use the Mondeo throttle body which happily bolts on to the 1.6 inlet manifold. You do however have to swap over the throttle linkage and the cable retaining plate from the Fiesta Throttle Body. I was told this is a straight swap but in my case this was only partially true as I found I had to cut/file lumps off the cable retaining plate and also found I had to file out the main throttle linkage bore as the Fiesta one is too small for the Mondeo spigot. I think I could just have swapped the spigots over but just could not undo them.
Just a bit more detail to add here, i carried out this section on a mondeo throttle body today to use on my 2000cc Zetec Turbo, the spigots cannot be swapped over, the 1800 throttle bodies spigot has a smaller diameter threaded section than the mondeos. I also filed out the plastic main throttle linkage bore to fit the mondeo spigot. I also found that the cable retaining plate took alot of work to adjust to fit, and i cannot get the lower bolt in a hole on the plate, at the moment it simply grips the plate around the edge like a clamp using the torx head screw and a large washer.
Thanks
Matt
- StreetDragster
- Elite Post Master
- Posts: 1420
- Joined: Mon Aug 11, 2003 9:51 am
- Location: Blackpool
by paulbaker on Wed Apr 21, 2004 2:52 pm
XR2iTony :what exactly would i need to change to drop a focus 2l into my 1.6 XR2i?
Assuming it is a Zetec based one just what I have put in my guide. If it's a CVH based one then it is a deal harder as you will have to also change the loom
IT WAS A FIESTA--UNTIL--THE ULTIMATE FEZ BODY KIT!!!
QUANTUM H4--2.0 ZETEC POWER--ALL I WANT FOR CHRISTMAS IS A NOS KIT
QUANTUM H4--2.0 ZETEC POWER--ALL I WANT FOR CHRISTMAS IS A NOS KIT
- paulbaker
- Poster
- Posts: 108
- Joined: Thu Jun 13, 2002 9:30 am
- Location: Warrington
- XR2i Chick
- SeXR2i RAHHH!!!
- Posts: 3362
- Joined: Thu Jan 01, 1970 1:00 am
- Location: Somewhere, Over the rainbow... Drives:-Red Diesel Shed (for now!)
by adz on Thu Nov 04, 2004 11:16 am
one problem, insuring it 
lol, im only 17 so im not going to be doing anything like this for a good few years. how old are you and who are you insured with if u dont mind me asking?
ive always been interested in doing something like this since renton (redline) put a cosworth engine in his bmw (see sig)
also my mate put an r5gt turbo engine in his clio (see video)
http://www.1an.co.uk/adey/100_0532.mov
cheers
adz
lol, im only 17 so im not going to be doing anything like this for a good few years. how old are you and who are you insured with if u dont mind me asking?
ive always been interested in doing something like this since renton (redline) put a cosworth engine in his bmw (see sig)
also my mate put an r5gt turbo engine in his clio (see video)
http://www.1an.co.uk/adey/100_0532.mov
cheers
adz
- adz
- Elite Post Master
- Posts: 5449
- Joined: Wed Oct 20, 2004 11:39 pm
- Location: gloucester Drives:mk1 jetta
123 posts • Page 1 of 4 • 1, 2, 3, 4
Twitter
The second 20th Anniversary article, a dive into the history of how the site came about is available here: https://t.co/kbCfZ4sf0R
17:44, 4th December 2021 Twitter Web App
To celebrate https://t.co/wXVkvJipaS being 20 years old this year, I've written a series of articles detailing the… https://t.co/B0vE0Y3KvP
17:42, 4th December 2021 Twitter Web App
Follow fiestaturbo.com on Twitter:
http://twitter.com/fiestaturbo/
Facebook
New article! fiestaturbo.com is 20 years old this year and I'm writing a series delving into the history of it. …
Saturday, 4th December 2021 12:49
Some awesome Escorts from the Fair - FORD FAIR 2021: ESCORT EXHIBITION - …
Sunday, 31st October 2021 17:05
All the best Focuses from Ford Fair - FORD FAIR 2021: FOCUS PEEKING - Which was your …
Thursday, 7th October 2021 22:21
Become a fan:
http://www.facebook.com/fiestaturbo/
RSS Feeds
Subscribe to the RSS feed
What is RSS?
RSS is a technology that lets you use special applications or modern browsers to notify you you when a site is updated. You can then read the updated content in that application or your browser.
To subscribe to these RSS feeds you need to copy the links above. For instructions on how to add it to the feeds you keep track of, consult the documentation of your RSS reader.