Willka

Hi Guys,

Im the proud new owner of a Ford KA and want to do a Puma 1.7 engine swap. I have searched through every thread i could find about engine swapped KA's but just have a few questions left

I have never done an engine swap before but pretty sure i can manage everything else but the wiring scares me, does anyone have a quick introduction into how to splice the two looms. Do i run both ECU's and just let the Puma control the engine?

Does anyone have a guide on how its done? I have purchased Haynes manuals for both cars but it feels daunting!

Thanks for any input

Will,

Rubber244

Hi pal, I'm half way through my puma/ka conversion, but still have loads of questions, could you direct me to some links as I'm having trouble finding some! Thanks

Willka

Hi mate,

I have collected useful bits from a couple of forums, hope it helps. Some of them are from 2.0 or 1.8 Zetec builds but i still found their process useful:


Useful info:
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http://www.fk-oc.com/index.php?/topi...d-racing-puka/
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engine was off ebay listed shit come with 6k in paperwork from the build but they didnt take it out well the cut the loom so i got a

puma loom and went from there as for the mount's i made mine as they fucked the old ones up it's a ally spacer plate on the battery

tray oh battery ha to be moved to the boot, its a puma box with ka bell housing using puma shafts that have to be shortened you also

need custom header tank and custom rad i have the spec's if needed had the engine mounted in the 1st day but took it out again and

remounted oh also had to remove the bonnet supports so it would shut where are you based i will be able to help with most things as

very fresh in my mined



http://www.feoc-uk.org/forums/?showtopic=64618
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Was there much faffing with custom mounts, or were you able to nick mounts off something else and maybe have to modify them?

Two of the mounts are on the gearbox, so bolt straight on.
The problem is the drivers side mount. There are are several options:

1) I am Using a "blakey" mount - a cast bracket designed by a guy called Lee Blake who I believe was one of the first to fit a 1.6 CVH turbo into a Ka. The bracket mounts straight to the normal Ka mounting points on the chassis leg. This is designed for the CVH, so the cast part needs grinding back to clear the pulleys on the Zetec engine. Also the rubber mounting bracket for the back of the engine needs modifying as the hole pattern is different to the Zetec. I am hoping to be able to use the original RS1800 Engine side of the mount, coupled with the modified cast bracket.

2) There is a Guy called Joey-P who makes mounts (was in Fast ford a few months ago with his Focus RS engined Ka - 313bhp and 157mph :-O) . His version uses the blakey cast bracket, but with all the machining already done to clear the pulleys. He also supplies the modified engine bracket to bolt straight onto the Zetec. This sells for Ł245 as a complete package.

http://www.trackdesi...rd-ka-parts.htm

3) You can just fabricate your own mount. I think the most common is to use a modified CVH bracket on the back of the engine, then just weld a sturdy piece of steel to the chassis leg with a hole in to accept the pin of the engine mount.

I'm not 100% convinced by the cast alloy bracket, so I'm going to look at designing a new bracket from scratch. This will be a bit in the future though, once I've finished getting the engine in!



http://www.fk-oc.com/index.php?/topi...ne-conversion/
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The gearbox mount is different but it's easy to make a braket to adapt it, the engine mount looks easy too, I mocked this up using photos which looks like it should br straight forward:

Posted Image

which won't cost much, I'd budget ÂŁ150 for doing them if I were doing it myself

As the Puma has the same floorpan as the Ka you can use the standard exhaust but as the puma is longer you chop the tailpipe - ÂŁ0

Splice the 1.7 loom into the KA loom so you get 12v, switched 12v etc from the original ecu then things like the oil pressure switch, alternator warning etc get chopped into the Ka loom to connect to the dashboard, puma loom controls the fuel pump.... you can work this out with wiring diagrams for both looms/ecus then double/tripple check them on the actual Ka and Puma looms then get snipping!

Ka radiator will probably be fine but could benefit from running a manual switch for the fans, you might have to chop up some coolant hoses to re-route them but that's not all that expensive unless you need to use silicone, if you do just buy the bends then use hard pipes, I'd budget ÂŁ100 for the hoses and joiners etc.

You need to account for zip ties, jubilee clips, wires, heat shrink, fresh coolant, oil, plugs, leads, filters, water pump, cambelt, brake fluid, gearbox oil new tools etc. etc. it's this stuff that takes you up the wrong'un when you've not done a conversion before

Oh, use the puma front brakes on the Ka too!


http://s281.photobucket.com/user/Dav...?sort=3&page=1
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Zetec swap pics


http://www.fk-oc.com/index.php?/topi...-loom-into-ka/
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See picture
i dont no how well you can see but this is what the puma loom looks like after it's been modded you only use the engine loom and half the under bonet fuse box and there's only 4 wires then that you need to splice into the ka loom oh i have given up on getting the fan to work automatically and put it on a switch


https://passionford.com/forum/restor...c-project.html
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Great writeup


passionford.com/forum/restorations-rebuilds-and-projects/423042-ka-zetec-project-2.html
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Engine removal guide:

to just remove the ka lump you need a 13mm spanner , 13mm socket and rachet ,and a torx 55 bit which you can connect to a rachet .

pliers to remove all the water pipe clips
small electrical screw driver to remove the clutch fluid clip from gearbox
3 bolts holding the gear selector rods to the box and then just various wiring plugs to unplug.

engine crane to lower engine down then lift the car up and pull engine out from underneith , u also need to do this to fit the zetec engine.

to fit zetec engine you dont need a great deal

you need a custom mount plate for drivers side
an escort rs turbo rubber mount and backing cup (which needs moddifying to fit )
the other 2 engine mounts are on the ka gearbox

you need to cut the slam panel to give room for the exhaust cam and plastic cam cover when you fit it.



http://www.fk-oc.com/index.php?/topi...engine-mounts/
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Puma Mount:
This is the ka mount you see under the hoses, making an adapter which bolts to this then bolts to the engine means you can retain the KA's rubber mount, actually, I recon the bolt spacing on the 2 end bolts on the puma mount look like they'll line up with left-most two holes on the ka mount so you might be able to chop the right hole off the ka mount and bolt it together without an adapter






http://www.fk-oc.com/index.php?/topi...fitting-dials/
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Fitting Sportka clocks


http://www.talkford.com/community/to...70-conversion/
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Once you've got the ECU and engine loom, you'll need to connect them to the ka loom. The wires that will need connecting to get the engine running is...


Constant live (battery)
Switched ignition live
Fuel pump earth
Earth
Rev Counter & other gauges

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Enjoy

Will,

Rubber244

Sweet, very helpful, nice one buddy! 👍
I've already ripped the puma apart and got everything I need, im just about to start ripping the ka apart, pics posted soon! Thanks for the info bro!

CrOwSoN15

Always thought this would be a cracking swap, far lighter than a 2.0 Zetec and nigh on identical power output, great fun in a little KA.

Willka

Really looking forward to it, found a few other people that easily got 140-150 from the 1.7. My plans eventually will be cams, head skimming, port and polish and then either a FRP ecu or getting the current remapped.

Should make for some decent gains. Cant wait to start ripping into them, just hoping for some advice from somebody experienced in this swap

Willka

Ive started a project thread that can be found here:

https://passionford.com/forum/restor...onversion.html

Getting through it!