fiestaturbo.com

[leighk2010]

Hiya guys and girls of Fiesta turbo
Well here is my project, its a 2001 panther black zetec s.

Current spec:

• Poly bushed all round
• New drop link and track road ends
• Brand new ap coilovers
• Battery relocation to boot
• Rear harness bar
• Floor plates fitted for omp 10 point bolt in cage
• Flocked dash cut for cage

The plans for the car:

• Omp 10 point cage
• 300mm front brakes
• Poloycarb windows all round
• False floor
• Carbon door cards
• Carbon rear door cards
• 2.0 black top zetec engine

Then later on when it all running nice and sweet plan on turbo or supercharging the zetec engine,

Hope you will all enjoy watching this project unfold and hopefully will be seeing some of you on track next year

[rst-steve]

Looks like a good base to start on, should be a proper little beast when done!

[leighk2010]

Looks like a good base to start on, should be a proper little beast when done!

cheers mate i hope it is too, only problem atm is i mite have to go on the sick from work so money is going to be very tight

[leighk2010]

well thanks to jonyb4 have now got the size of what the ecu should be have have order this
http://cgi.ebay.co.uk/ws/eBayISAPI.dll? ... _903wt_905

plans is to use the ecu cage inside this box so i can then attach the stranded si loom using the bolts which you would if were bolting it in place on the scuttle pannel and this will then allow me to mount the ecu in the engine bay out the way why still using the rubber to keep all the wires sealed will get pics up soon as it comes thought the post and have cage fitted inside box

[jonyb4]

Ah the project looks good so far mate, that box shall do the trick too you could wrap the ecu in bubble wrap once in the box

[leighk2010]

well this weekend been quite busy have managed to get a few things done

• Removed power steering pump and all pipes ready for manual rack
• Fitted set of 15’s i have got to get ride of the 17’s which were on it
• Tidying up power cable to battery box
• Removed original mount for zs and start to make a mock mount for the black top engine

Here is the pics of weekends work also need to get spacers for the wheels as you can see there touching the shocks

Power cable:





The wheels



Spacer defo needed


Removing zs mount and mock up for 2.0 black top

[jonyb4]

looking good

whats that box for?

if your converting to manual steering, i have a manual rack - colomn union i can sell ya gimme a Pm

i migh still have my rack too ill have tohave a looky

[leighk2010]

looking good

whats that box for?

if your converting to manual steering, i have a manual rack - colomn union i can sell ya gimme a Pm

i migh still have my rack too ill have tohave a looky

the one made of card? its just a mock up to were the mount will go as going to be using the focus black top mount, once the mount is made at right hight etc just need to drill a hole and weld a nut and the focus mount will screw straight down to it. obv need to make it a metal one up first but waiting till get my hands on a black top first to make sure its all in the right place. Cardboard mock up lot cheaper than metal if aint right lol. Quite simple rather than doing what you had to do for the silver top conversion

and pm sent

[jonyb4]

yea the silvertop one was a bit messy, atleast with the blacktop one you can make one up, and when your making it you can be nice and tidy, mine was eugh in a way, and i was in a rush to get it done so i didnt even paint or grind the welds back

my next similar job liek that will be done right


what gearbox are you thinking about then? i dont think the zetec bolts up to a Sigma/SE box i never tried but the diesel Lynx gearbox will, and so does the HCS, and i can vouch (SP) that the 1.3 hcs gearbox in lowmilage (less than 90k) will be strong enough to hold 130bhp, its a strong box. and it will bolt up to the car on the original mounts, but the clutch options are limited, or are you fabricating your own gearbox mount for a different box?


you want to look around some breakers for a 2.0 focus or mondeo mk3 for that engine

[leighk2010]

yea the silvertop one was a bit messy, atleast with the blacktop one you can make one up, and when your making it you can be nice and tidy, mine was eugh in a way, and i was in a rush to get it done so i didnt even paint or grind the welds back

my next similar job liek that will be done right


what gearbox are you thinking about then? i dont think the zetec bolts up to a Sigma/SE box i never tried but the diesel Lynx gearbox will, and so does the HCS, and i can vouch (SP) that the 1.3 hcs gearbox in lowmilage (less than 90k) will be strong enough to hold 130bhp, its a strong box. and it will bolt up to the car on the original mounts, but the clutch options are limited, or are you fabricating your own gearbox mount for a different box?


you want to look around some breakers for a 2.0 focus or mondeo mk3 for that engine

my aim is to keep it looking tidy one i got all the work dun the bay will be getting some freash paint

and going for the zs box as i have one which come with the car been told it does bolt up and if not with a ka bell housing it will but also looking into frp boxes with limited slip diff ten if all else fails will just make a custom mout up and go for a stronger box as later down the line i think i going to go for a supercharger

[Pumatt]

Looking good so far mate, from what I've heard the puma gearbox (including the racing puma) wont fit. There was a turbo'd zetec silvertop puma in fast ford a year or so ago, She had a Fiesta diesel gear box and a uprated clutch. I think it was running over 200bhp so you may be okay with that option.
As for the 1.3 gearbox from fiestas and KA's, I'm not sure how much power these will take. 130bhp jon had in his was okay but the clutch was eatten up after a few thousand miles.

There has been a few people converting mk3 fiestas with zetecs to have a 6 speed st170 gear box. Depending on your budget that may be a future idea?

[Pumatt]

Oh, and how much was that flocked dash?, out of curiousity. Always wanted one

[jonyb4]

Remember the one at fitp on sale for 80 quid

[leighk2010]

Oh, and how much was that flocked dash?, out of curiousity. Always wanted one

sorry mate wish could help but the dash was already flocked when i picked the shell up think its around £100 quid tho

[Pumatt]

Ahh thats not bad, and i remeber seing them at fiesta in the park, but forgot how much they were.

[leighk2010]

Todays up date

Take one box


Cut out a section



Still needs to be tidied up

Add one bracket


Add ecu


And then the wiring from the 2.0 loom joins straight on and gives me a water proof seal and box to house in the engine bay for the 2.0 ecu



And now the fun part zs engine bay fuse box and loom to sort out and trim down as non of the engine bits from the zs loom will now be needed

[jonyb4]

did you say 2.0 loom?

do your self a favor mate and just obtain a mk3 1.6 Si loom, its far simpler and will do the job perfectly, and so far the only sensor unused would be the PAS sensor plug, since your removing it

box looks good, beats my cardboard box and bubble wrap llama

[leighk2010]

did you say 2.0 loom?

do your self a favor mate and just obtain a mk3 1.6 Si loom, its far simpler and will do the job perfectly, and so far the only sensor unused would be the PAS sensor plug, since your removing it

box looks good, beats my cardboard box and bubble wrap llama

cheer mate thats why i got the box

and i ment si loom lol

and there will be quit a bit to remove of the zs loom as will not need the engine bay loom off the zs any more as it will only be running the inside of the car not the engine so no use having it lieing around when not needed

[Excursion]

No, don't get an Si loom.

You don't need to use that box, either. Use your ZS loom then you can retain ECU fan control and your engine bay fuse box. The ZS ECU is a 60 Pin EECV so all you really need to do is swap a few pins around to suit the 2.0 EECIV pinout.

[leighk2010]

No, don't get an Si loom.

You don't need to use that box, either. Use your ZS loom then you can retain ECU fan control and your engine bay fuse box. The ZS ECU is a 60 Pin EECV so all you really need to do is swap a few pins around to suit the 2.0 EECIV pinout.

interesting i heard was best to do the 2 ecu method do you have any more info on this mate would it be similar to what ya have to do to run a zetec in a escort as believe that's all they have to do? and would all the zs loom connectors fit the black top engine?

you are right tho it does use a 60 pin type connection

[Excursion]

No, don't get an Si loom.

You don't need to use that box, either. Use your ZS loom then you can retain ECU fan control and your engine bay fuse box. The ZS ECU is a 60 Pin EECV so all you really need to do is swap a few pins around to suit the 2.0 EECIV pinout.

interesting i heard was best to do the 2 ecu method do you have any more info on this mate would it be similar to what ya have to do to run a zetec in a escort as believe that's all they have to do? and would all the zs loom connectors fit the black top engine?

you are right tho it does use a 60 pin type connection

I haven't read all of this, but is it a track car? Do you need to keep PATS? The only problem with EECIV is most are external PATS, and as you probably know your EECV is internal PATS: you will loose PATS if you run solely on the EECIV ECU.

Why did you think about using two ECU's - EECV for PATS and EECIV to run the engine?

[leighk2010]

No, don't get an Si loom.

You don't need to use that box, either. Use your ZS loom then you can retain ECU fan control and your engine bay fuse box. The ZS ECU is a 60 Pin EECV so all you really need to do is swap a few pins around to suit the 2.0 EECIV pinout.

interesting i heard was best to do the 2 ecu method do you have any more info on this mate would it be similar to what ya have to do to run a zetec in a escort as believe that's all they have to do? and would all the zs loom connectors fit the black top engine?

you are right tho it does use a 60 pin type connection

I haven't read all of this, but is it a track car? Do you need to keep PATS? The only problem with EECIV is most are external PATS, and as you probably know your EECV is internal PATS: you will loose PATS if you run solely on the EECIV ECU.

Why did you think about using two ECU's - EECV for PATS and EECIV to run the engine?

it will be more road/ used on track when i get chance what does pats really control? and yes am aware the EECV is internal pats

and yes that was the plans with running the 2 ECU's

[Excursion]

it will be more road/ used on track when i get chance what does pats really control? and yes am aware the EECV is internal pats

and yes that was the plans with running the 2 ECU's

Your call then really, if you must use EECIV then either keep PATS by using two ECUs or use one ECU and bin it. If you bin it then you can use your existing loom by swapping a few pins around.

I just created the following charts for you; I was going to do exactly the same thing as you before I decided on a different route. Save them to your desktop and you can view the entire image:



In my opinion, using EECIV in a Mk4/mk5 is a big step backwards, and the two ECU method to get around PATS is a mess/bodge.

I was going to use a black top, and run the black top from EECV 60 Pin Focus 2.0 management (Manual gearbox - Automatic is 104 pin version). This way I ended up with a better ECU, PATS and without the need to make substantial wiring changes! I'm now building a ZT and will use 104 pin management, so never went this way in the end.

[leighk2010]

it will be more road/ used on track when i get chance what does pats really control? and yes am aware the EECV is internal pats

and yes that was the plans with running the 2 ECU's

Your call then really, if you must use EECV then either keep PATS by using two ECUs or use one ECU and bin it. If you bin it then you can use your existing loom by swapping a few pins around.


In my opinion, using EECIV in a Mk4/mk5 is a big step backwards, and the two ECU method to get around PATS is a mess/bodge.

I was going to use a black top, and run the black top from EECV 60 Pin Focus 2.0 management (Manual gearbox - Automatic is 104 pin version). This way I ended up with a better ECU, PATS and without the need to make substantial wiring changes! I'm now building a ZT and will use 104 pin management, so never went this way in the end.

i was thinking of using the eeciv to get around pats as you have said but i'm not to cluded up what ecu to use with the black top a guy on zsoc has told me to go the two ecu method and use the si loom and slice it in,

what ecu would you say is best then.?

the plan is 2.0 black top into my zetec s shell i brought and interested in what you have said about the focus ecu if it meens i could keep the pats as well this is my first engine swap like this and want to do it the best i can rather than juat bodge it to get it to work so all you input is amazing as read a lot of stuff you have done on here and you seem a very smart guy and will trust what ever you say other other people.

so what is this focus ecu method then please explain

[jonyb4]

mark its not that its a bodge way, its simply down to the fact me, and leigh here dont have the understanding you have of the EECIV and V wiring looms and ecu's also pats

it works and if you can keep the wiring and ecu tidy its far from a bodge set up, use solders not scotch blocks, tape/mask all the joinings and keep the wires tiding in cable ties etc and it will be fine, only downside is you have to explain the 'whats that box for?'

plenty have done similar with their Ka's, and ive seem alot worse, one guy at fitp had tights over his maf sicne he didnt have room for a filter under the tiny ka bonnet

[Excursion]

i was thinking of using the eeciv to get around pats as you have said but i'm not to cluded up what ecu to use with the black top a guy on zsoc has told me to go the two ecu method and use the si loom and slice it in,

what ecu would you say is best then.?

the plan is 2.0 black top into my zetec s shell i brought and interested in what you have said about the focus ecu if it meens i could keep the pats as well this is my first engine swap like this and want to do it the best i can rather than juat bodge it to get it to work so all you input is amazing as read a lot of stuff you have done on here and you seem a very smart guy and will trust what ever you say other other people.

so what is this focus ecu method then please explain

The 'Black Top' always ran on EECV, your car is wired for 60 pin EECV (Zetec ECU is code CHCA if I recall) so I recommend you use a EECV ECU designed for the 2.0 Zetec.

I did a lot of research on this and checked the wiring diagrams for a lot of Zetec engined EECV cars, and just like the EECIV ECUs, the pin outs for the EECV ECUs remain pretty much identical across the range; so just like us Mk3 guys can swap an Si ECU for a 2.0 Mondeo ECU, you guys with a ZS can run a 2.0 Focus ECU in place of your ZS 1.6 ECU.

Here's the proof:


I only found the following mis-matches between ZS and Focus 2.0:


Pins:

• 2, 23 | Knock sensor | Ignore: the 2.0 Black Top doesn't use one. No modifications are required, the plug can be left in your loom
• 41 |Alternator | Ignore: the focus has ECU controlled charging, not present on ZS.
• 45 |Alternator | I suspect you can ignore this despite the pin number on the alternator being different, I think its only because the Focus uses a 3 pin plug rather than 2 pin, but this function should be identical between Focus and Fiesta.
• 4 |Tacho
• 35 |ECT - Engine Coolant Temp

The last two are a special case, the Zetec-S instrument cluster has a separate feed from the ECU for coolant temp and the tacho. The Focus uses a data bus called SCP to transmit this data to the instrument cluster. To simplify, the focus transmits instrument cluster data over a bus (like a computer network), whereas the Fiesta uses separate wires for each warning lamp and instrument.

I do not know if the Focus ECU outputs sensor information in a non-SCP bus format, therefore you would need to try this out. If it doesn't. then you'll need to either use a Focus instrument cluster, or wire your rev counter and temp gauge directly to the engine bay.

See this item here: http://cgi.ebay.co.uk/Focus-Mk1-98-04-2 ... 1c165dff70

Plug that into your ZS loom, take the PATS chip from the key supplied with the ECU and swap it with the PATS chip in your ZS key - and there you go - no (or hardly any!) wiring changes required! You can then sell a ZS ECU and chip and probably get back what you paid for the 2.0 setup

PS EEC = Electronic Engine Control, the Roman numerals following this denote the generation.

[Excursion]

mark its not that its a bodge way, its simply down to the fact me, and leigh here dont have the understanding you have of the EECIV and V wiring looms and ecu's also pats

it works and if you can keep the wiring and ecu tidy its far from a bodge set up, use solders not scotch blocks, tape/mask all the joinings and keep the wires tiding in cable ties etc and it will be fine, only downside is you have to explain the 'whats that box for?'

plenty have done similar with their Ka's, and ive seem alot worse, one guy at fitp had tights over his maf sicne he didnt have room for a filter under the tiny ka bonnet

Jon - all this info can be pulled from the Ford TIS wiring diagrams, which are widely available, even on eBay I think. I don't have any access to information that everyone else doesn't.

Using two ECUs is a bodge for the reasons I gave; these other people haven't done their research

[leighk2010]

i was thinking of using the eeciv to get around pats as you have said but i'm not to cluded up what ecu to use with the black top a guy on zsoc has told me to go the two ecu method and use the si loom and slice it in,

what ecu would you say is best then.?

the plan is 2.0 black top into my zetec s shell i brought and interested in what you have said about the focus ecu if it meens i could keep the pats as well this is my first engine swap like this and want to do it the best i can rather than juat bodge it to get it to work so all you input is amazing as read a lot of stuff you have done on here and you seem a very smart guy and will trust what ever you say other other people.

so what is this focus ecu method then please explain

The 'Black Top' always ran on EECV, your car is wired for 60 pin EECV (Zetec ECU is code CHCA if I recall) so I recommend you use a EECV ECU designed for the 2.0 Zetec.

I did a lot of research on this and checked the wiring diagrams for a lot of Zetec engined EECV cars, and just like the EECIV ECUs, the pin outs for the EECV ECUs remain pretty much identical across the range; so just like us Mk3 guys can swap an Si ECU for a 2.0 Mondeo ECU, you guys with a ZS can run a 2.0 Focus ECU in place of your ZS 1.6 ECU.

Here's the proof:


I only found the following mis-matches between ZS and Focus 2.0:


Pins:

• 2, 23 | Knock sensor | Ignore: the 2.0 Black Top doesn't use one. No modifications are required, the plug can be left in your loom
• 41 |Alternator | Ignore: the focus has ECU controlled charging, not present on ZS.
• 45 |Alternator | I suspect you can ignore this despite the pin number on the alternator being different, I think its only because the Focus uses a 3 pin plug rather than 2 pin, but this function should be identical between Focus and Fiesta.
• 4 |Tacho
• 35 |ECT - Engine Coolant Temp

The last two are a special case, the Zetec-S instrument cluster has a separate feed from the ECU for coolant temp and the tacho. The Focus uses a data bus called SCP to transmit this data to the instrument cluster. To simplify, the focus transmits instrument cluster data over a bus (like a computer network), whereas the Fiesta uses separate wires for each warning lamp and instrument.

I do not know if the Focus ECU outputs sensor information in a non-SCP bus format, therefore you would need to try this out. If it doesn't. then you'll need to either use a Focus instrument cluster, or wire your rev counter and temp gauge directly to the engine bay.

See this item here: http://cgi.ebay.co.uk/Focus-Mk1-98-04-2 ... 1c165dff70

Plug that into your ZS loom, take the PATS chip from the key supplied with the ECU and swap it with the PATS chip in your ZS key - and there you go - no (or hardly any!) wiring changes required! You can then sell a ZS ECU and chip and probably get back what you paid for the 2.0 setup

PS EEC = Electronic Engine Control, the Roman numerals following this denote the generation.

wow thank you for that mark top bloke so no real need to change pin set up for the focus eecv and then if the the tacho and temp gauge do not work just a case of adding some wires to them

really making me glade i went blacktop now rather than silvertop as i was going to

so will all the connectors of the zs loom fit straight onto the black top eg coil pack cam sensor etc?

[frst toady]

you cant educate pork tho mate

[Excursion]

wow thank you for that mark top bloke so no real need to change pin set up for the focus eecv and then if the the tacho and temp gauge do not work just a case of adding some wires to them

really making me glade i went blacktop now rather than silvertop as i was going to

so will all the connectors of the zs loom fit straight onto the black top eg coil pack cam sensor etc?

You could run a silver top off of EECV, I was going to do that at some point. You just have to change the TPS and ISCV for black top versions

Yes, the connectors from the ZS will fit the black top. That's the beauty of it

[leighk18]

wow thank you for that mark top bloke so no real need to change pin set up for the focus eecv and then if the the tacho and temp gauge do not work just a case of adding some wires to them

really making me glade i went blacktop now rather than silvertop as i was going to

so will all the connectors of the zs loom fit straight onto the black top eg coil pack cam sensor etc?

You could run a silver top off of EECV, I was going to do that at some point. You just have to change the TPS and ISCV for black top versions

Yes, the connectors from the ZS will fit the black top. That's the beauty of it

cheers again mark you been a great help your a credit to this site so guess its time to sell the si loom now then, good job you posted this in here before i stared chopping away at the zs loom finger crossed it all worked if i get payed enuff on friday ill buy that ecu you sent me in the link

[jonyb4]

wow thank you for that mark top bloke so no real need to change pin set up for the focus eecv and then if the the tacho and temp gauge do not work just a case of adding some wires to them

really making me glade i went blacktop now rather than silvertop as i was going to

so will all the connectors of the zs loom fit straight onto the black top eg coil pack cam sensor etc?

You could run a silver top off of EECV, I was going to do that at some point. You just have to change the TPS and ISCV for black top versions

Yes, the connectors from the ZS will fit the black top. That's the beauty of it

mark your purely a genious, no other word for it

really making me glade i went blacktop now rather than silvertop as i was going to

in this sence, your trading low costs, and ease of finding parts/engines for fewer milage and refinability

the smarter version of this would be to do what mark said, get a silvertop and run it on a blacktop loom and ecu, but if money isnt your issue carry on with the blacktop, the mount seems a bit simpler, but involves more work and the refinement once done will be rewarding itself

you cant educate pork tho mate

are you looking for a slap??

[leighk2010]

wow thank you for that mark top bloke so no real need to change pin set up for the focus eecv and then if the the tacho and temp gauge do not work just a case of adding some wires to them

really making me glade i went blacktop now rather than silvertop as i was going to

so will all the connectors of the zs loom fit straight onto the black top eg coil pack cam sensor etc?

You could run a silver top off of EECV, I was going to do that at some point. You just have to change the TPS and ISCV for black top versions

Yes, the connectors from the ZS will fit the black top. That's the beauty of it

mark your purely a genious, no other word for it

really making me glade i went blacktop now rather than silvertop as i was going to

in this sence, your trading low costs, and ease of finding parts/engines for fewer milage and refinability

the smarter version of this would be to do what mark said, get a silvertop and run it on a blacktop loom and ecu, but if money isnt your issue carry on with the blacktop, the mount seems a bit simpler, but involves more work and the refinement once done will be rewarding itself

you cant educate pork tho mate

are you looking for a slap??

lol jonhny mark just said i could use it on the sliver op setup but im going blacktop any way a the slivertop engine i have hear needs a full rebuild any way so blacktop it is and also with the blacktop mount in place i could also fit focus rs engine or st170 if i so wished

[jonyb4]

yea i know that, what i was saying is, it will be more expensive to go blacktop, its a newer engine, and mostly because ti come in the focus and mondeo mainly, both are still quite expensive still, focus 2.0l are still over 1.5k. mondeo mk3's are similar

[leighk2010]

also mark i'm wanting to remove the abs from the zs what is best way to go about this? ill be running 300mm Mondeo mk3 cailpers so is it best to get a non abs servo etc and then cut out any wiring for the abs from the loom why its out the car?