fiestaturbo.com

[jonyb4]

I know some ppl are interested in a parts list needed for this conversion, maybe a little early considering it aint in and running quite yet but none the less

ok brief of parts, bearing in mind this is for the engine i have bought, 1997 Escort series 2 "silvertop" Zetec E, this is a 1800cc model all with DOHC 16v with 115ps, my particular engine does not come EGR valve (Exhaust Gas Recirculation valve) equiped
some consider this to be a waste of engine power and resources, the idea of egr is to recirculate any unburned fuel by allowing a portion of the exhaust gasses to once again enter the cylnders to be reburnt to help save the catalitic converter and in turn your emissions

you can buy Bungs to block off the valves in the exhaust manifold if yours has an EGR valve fitted and you do not wish to keep it

this parts list applies to a Mk4 fiesta or mk5, this is a rarely done conversion as the duratec is a more popular "power" option
this can apply to the 1.6 90ps, 1.8 105ps 115ps and 130ps engine and the 2.0 136ps from a mondeo
if your engine is already removed from a fiesta mk3 most rthese parts will already be fitted and wont apply
engines from a escort and mondeo will, and even more parts are needed for the 2.0

ok so assuming your engine is from an escort this is the parts list

Most the parts you will need can be obtained from a fiesta 1.6 Si /escort 1.6 finesse or similar the fiesta XR2i 16v or RS1800

to start with you need the engine


the inlet manifold, this is the CAST unit from a 1.6 si (fiesta or escort) but this will hinder a 1.8 or 2.0, can also be found on a escort mk5 XR3i Cabrio (obviously xr2i and rs1800


fiesta Zetec rear engine mount, both this piece containing the rubber and the engine bracket these bolt together


the related ECU for your choosen engine, im not aware of all theyre names, i think such a 1.6 one is a GURU?, my 1.8 one uses a JEST, and i know some 2.0 ones are DEEP, DESK, DEWY maybe others



the assocated Maf


ilet piping but a K&N 57i kit or similar products will do nicely, the rubber pipe on the end of this standard unit will either need streching over the bigger 1.8/2.0 maf or a new piece bought, such as a silicon 60/70mm reducer pipe, ebay has loads of shops selling them


(for me as im doing a PAS conversion also) a PAS fluid cooler/radiator
mk3 item


mk4 item


PAS fluid resevor


the suited piping

(not fully determind as of yet) fiesta 1.6 si radiator fan


and radiator itself


heatshield and coolant piping


Engine hoist if prefered


new cambelt kit if prefered


your mk4 gearbox and starter motor (need confirmation that the Zetec se/sigma gearbox has the same bolt pattern as a Zetec E)


PAS piping and sensor, mk3 fiesta zetec item


a bracket will need to be made to hold the driveshaft either bolts to the engine or the crossmembers steering rack mount


you need to weld the mk3 standard zetec mount to here on the mk4's turret, cut the mount out from a mk3 si


the mk4 engine mount will need to be removed and this plating cut out, but only the left half is nessesary, if you want to leave it for some ridigity thats fine


mk4 pas steering rack (for pas conversion)


PAS lower steering coloum and joint


a new auxilery bellt for a 1.6 fiesta si with pas (if applicable ) model, around £11 from motor factors

and will be a good idea to upgrade to bigger brakes to handle the extra power (double in my case)


and obviously you will need the fiesta Si 1.6 engine loom, all of it

as of now this is the complete list, hope it helps them who were interested

[MK3-MATT]

Get the disks skimmed mate, doesn't cost much and its worth doing

[jonyb4]

hmm good idea, however ia int a clue where i can get that done

[MK3-MATT]

Pretty much all garages do it, its not really a technical piece of equipment, just a spinning wheel and a sharp blade. Ring round your local garages and ask how much it will cost.

[jonyb4]

ah cheers mate

[MK3-MATT]

Deffo worth getting done, it basically puts a fresh cut surface on them so they should be good as new so long as they aren't warped or anything

[jonyb4]

apart from braking when theyre fitted, not sure what visuals to look for to see if they are, they seem fine

[lucasdemoley]

Coming along well matey.

Could be worth doing a full on seperate guide for this once you have finished, as its deffo an interesting conversion!

[jonyb4]

me and the owner of fiestagudies are gonna colaberate to make a guide im relying on his electrical know how

[dangerousdave]

i wouldnt skim the disks mate they may warp theres nothing wrong with yours! surface rust will come off when youve used the brakes 2 or 3 times

[jonyb4]

can anyone suggest the best course of action to repair this small patch of rust? its the only surface rust on my car and its recently turned into a hole and i know what rust here can do, id prefere not to have a plate put in, but if nessesary
its the passengers bottom corner of the windscreen


today i went back to the scrap yard for the third day in a row to get the PAS steering joint, cost 10quid


then back at home, i fitted the auxilery belt


the rest of my loom arived many thanks to Steveboy for suppling these at a generous price, also luckily he also supplied a bunch of spare sensors, as i needed to swap the thermostat temperature sensor


as you can see theyre very different

then started to prep the weld area for the mount, the guy will be here in the morning to weld the mount on



also cut out the required area of the orignal mount


i left in the middle of altering the front mount to fit, need to bend the back part


luckily the Lambda sensor on my 1.3 was able to fit the zetec as it was snapped, also plugs in fine, if it rough idles id probs point at this

more tomorrow

lol cheers dave, ill use a wire wheel on them first to make sure
i got to make a 3mm spacer for behind the disc for these

[dangerousdave]

i prob wouldnt even use a wire wheel if anything just fine grit paper will be fine cheap wet and dry! doesnt need to be perfect! like i said i wouldnt really bother! lol

if i were you id get the welder to sort that windscreen panel rot out buddy while hes there:)

[jonyb4]

nah my mig can do that job fine, only using this guy as he has a more powerful mig than i

hows the Zetec turbo coming lately mate?

[dangerousdave]

nah my mig can do that job fine, only using this guy as he has a more powerful mig than i

hows the Zetec turbo coming lately mate?

making inlet adaptors up still mate, done one of them still one to do! so progress has slowed down now

giving the rest of you a chance! liking your project mate! dont see many round like that!

[jonyb4]

lol best hurry up mate, ill be finishingbefore you get the engine in otherwise

cheers mate, means alot

[jonyb4]

guy popped round at 10 to sort the mount out, fantastic job i must say, hes a professional welder, makes gates etc privately
in action


done



after some struggling with my braided lines not leaving the caliper, but they did int he vice with mole grips


after 12mm drilling


will get on making spacers soon

[jonyb4]

my grampa knew a mate with a large lathe and used some emery cloth in it to take back the rust

they come back today, not a bad job at all, some of the heavyier rust is still there as they didnt want to scare the discs




this pic remidns me of saturns rings

[jonyb4]

engine is now ready to go in

replaced the cam cover gasket


and my Stainless steel rocker cover bolts come the otherday, so fitted them as i replaced the gasket



fitted starter motor and wired it up, i think thats how it wires



wired up the alternator, checked every plug is connected

what does this do?, does the oil breather hose go on it?


bridged the egr pipe ( although due to the mk4 loom, i will need to block one of these pipes off and connect the other to the loom, some kind of sensor)




wired in the engine grey plug to the loom, scarey wiring


and done


all this took me from 1 to 8pm

[- Danny Boy -]

Slowly getting there Jony! It will be in and running before you know it

[jonyb4]

ive now officially got a deadline lol, gotta be driveable by time for Go ape

[jonyb4]

The chap that done the mount welding come round at 10 to sort out the lower of the rear engine mount with a spacer, engine can now go in when ever im upto it, how ever i got some more of the wiring to finish, and i like to stand in the bay while doing it so i aint leaning over anything, and th bulk head is like my works bench

will probs get it in later on today and start connecting things back up, and repair my corroded battery + clamp

[jonyb4]

Ok LARGE update

the chap thats been doing the welding come round at 10 to make me a spacer for the rear mount bottom bolt - chassis leg, with the hole drilled i bolted it up ( he is also gonna be making me the V6 mondeo discs spacers, and the driveshaft brackets


then back to do some work now 1pm

then in with the engine


my mum was kind enough to pop tot he post office to collect my air filter, just a cheap item off ebay for now, which anoyingly the 76mm hose wont fit over my 80mm maf, so some negotiating make come into it


and for the first time ever, my engine is sitting in the car under its own parts


had to jack the gearbox up and remove the gearbox side of the mount to get it on easier, the hoist was lifting the engine squiff



then started to connect things up (fuel pipes are now fitted in reverese to this pic)


header tank


put the Si rad into the mk4 carrier, not an easy job making this all fit



drilled holes in the hangers/plates behind the rads mounts


some pipe work, anyone got some advice on how to tighten up the PAS pipes jubilee clip? cant get at it with the screw driver


due to having the HCS header tank, the overflow pipe is fitted towards the left of the tank, so had to reroute the zetecs one temperarly


taking shape


this aint right for a mk4, so was alter, cut the divider in half using a hacksaw then seperated them


for some reason this heater valve - radiator pipe was on the passengers side fo the engine, so rerouted it behind the engine passed the header tank and back to the rad


exhaust bolted on and heat shield in place, all pipes now fitted including the PAS piping





for those who did, still doubting it will let the bonnet shut?


fitted the Mk4 PAS cooler (decided agaisnt the mk3 item due to the mk4 having better mouting and being in better condition) i was gonna paint it in red VHT


And all done, even filled the PAS resevour, but will need topping back up once its running and filled the pipes and rack

The way the mk4 was MEANT to be made



heres a little Walk around video



And after 9 straight hours work, a very mucky face, a baboon my dad called me, i come in at half 12

Things left on the "to do list" include,
mount the drivers driveshaft in a custom made bracket
stretch or returna nd buy another 80mm air filter
stretch to fit the inlet rubber piece on tot he maf
buy a new clutch pipe retaining clip, a tiny yet vital part (unless the old turns up) and bleed clutch
fit brakes once the spacers are mate and i have drilled the passengers hub, bit braided lines and bracket them better, and bleed
make custom exhaust flexy and fit the 1.6 Si exhaust system and my same back box (originally made for a 2.0 si
refill trasmission fluid in the gearbox
refill the coolant
wire up the new feed to the Rev counter and tempurature gauge
sort out the relay for the fuel Pump tomorrow and then i gotta wait either for the escort key, or ill have t buy an RS1800 ECU or 2.0 (pre-pats)

Cheers

[~nomad~]

awesome! impressive stuff mate

[XRMike]

Looking great! Cant wait to see it finished!

[jonyb4]

awesome! impressive stuff mate

oo means alot coming from you mate

cheers mike, i cant wait either, but i keep having doubts if it will run, run bad, etc etc

first time doing a conversion, so im bound to have jitters i guess?

[jonyb4]

OH yea added to the parts list is a mk3 si 1.6 throttle cable, mine has plenty of slack in it, it pulls on the butterfply valve, but id not be openning it all the way

[MB7201]

Look good

The throttle cable wont solve that problem. The throw is different on the mk4 throttle body compared to the mk3 one. Its because theres the stopper under the throttle pedal which the mk3 doesnt have. You could either cut the stopper off (if you want to go that far ) or experiment with getting the linakge from an escort or mondeo to fit the throttle body (which possibly wont work as the cable comes in form a different direction).

Now might be a good time to see if the plastic inlet fits?

[Ruishy1]

love the work mate, nice your doing something from the norm

[knuckles]

hats off to you for going through with such a engine conversion with so many hurdles

[jonyb4]

cheers lads makes all the hard work seem more worth it when you hear comments like that

i think the cable bracket is made of steel, so il will weld some sort of extention to it, bring the reach out a bit, i bent it ealier and the cable is tight, but it pulls the bracket in when i push the pedal :@

seems it wasnt secured very well by the chap who made it

just need to sort this issue that is the pats for now

[Brammer]

can anyone suggest the best course of action to repair this small patch of rust? its the only surface rust on my car and its recently turned into a hole and i know what rust here can do, id prefere not to have a plate put in, but if nessesary
its the passengers bottom corner of the windscreen

I have seen what lies beneath these whole and it ain't pretty, your best bet is put a new wing on and underseal all behind it mate.

Keep the updates coming

[jonyb4]

would have thought that being drastic, its after all a very small hole and has only recently been a hole, if i dont sort it by the time its back on the road, ill slap some vaseline on it lol, my remedy for EVERYTHING

cheers though mate

[lucasdemoley]

:) cheers lads makes all the hard work seem more worth it when you hear comments like that

i think the cable bracket is made of steel, so il will weld some sort of extention to it, bring the reach out a bit, i bent it ealier and the cable is tight, but it pulls the bracket in when i push the pedal :@

seems it wasnt secured very well by the chap who made it

just need to sort this issue that is the pats for now

If your refering to the bracket that holds the cable, its like that because you are using a 2.0 tb, which meant you had to take appart the tb and exchange the throttle leaver on it with the 1.6 one, and it also meant you had to modify the 1.6 throttle cable holder as the 2.0 one was in a different position. Worked perfect on my car for years with no problems and is exacly how others have made theirs work. To say it wasn't 'secured very well by the chap who made it' is an unfair statment, just because it doesnt suit your application where you are putting it under extra pressure/ stress.

I would look at the options of again pulling appart the tb, and fitting your mk4 throttle leaver on it(might need abit of hollowing out like the 1.6 one did as the 2.0 tb has a chunkier connector bar thing). You could then attempt to mount the mk4 cable holder on it, and all this should give you the right amount of tb movement for the amount of pedal you give.

[jonyb4]

i didnt mean offence by it mate, but the torq screw used to hold it keeps wiggling free and the one on the lower of it isnt much better, so the plate can flext and even come out of place, all i need to do is gain more distance from where the cable links to, so i will weld a small extention piece to it

shouldnt need to go as far as swapping that part

thanks though

[- Danny Boy -]

This will be ace when its up and running Jony, just need to 130 spec it Powerrrrrrrrrrrrrrrrrrrrrrrrrrrrr as Clarkson says lol. Looks pretty dam sweet though, and will go nicely too when its up and running!