TomEbbs

After much umming and arrring.. I have decided (not recently) to rebuild and install a 2.0 into my 1.6 focus Of course it will have a sprinkling of uprated parts..

Heres the car:













Project 2.0 started in April of this year...

Couple of pics of the new Lump...






Turns out its form a 2000 Mondeo that had a nasty rear end shunt...

62k on the clock...

Got an st170 4-2-1 manifold in the post. Looks like its hardly been used..


only payed £40 so thats all good should be able to get it heat wrapped on monday.





Managed to start the heat wrapping on the exhaust while I was free this evening.


I was using the 2" stuff but ive decided that in future (and for the second half) im going to go with 1" as it would be easyer on the bends.

So this is where im at....





Ok so the strip down begins. Im a total novice at this so its a massive learning curve all this working with internal engine parts..

First off we needed to get the engine and gearbox separated.









With out too much hassle that was off. But it did reveal what a mess the inner bell housing was... So that needs a good clean up (is this a common thing?)

The clutch was in ok nick but i have another (along with a new thrust bearing which was checked to be the correct one ) ready to go on so thats fine.



But the flywheel needs a right good clean up.






It was then looking like this... Hung on the winch



Got hold of a engine stand to make things a bit easier so that will be in use as soon as i can get some long bolts to go through the bell housing / block holes in the engine.





Pulled the plug leads off and found out that it was flooded with water in the plug trench (not sure what its called) so dried all that out... apparently it had just came out of the car (yehh right ohh)

Next off came the inlet mani, Aux belt, pulleys and rocker cover to reveal...







So that was tonights antics in the garage. Its been a massive learning curve already so onwards and upwards...

The shopping list has an aux belt and tensioner now on the it The question is do i ditch the A/C as a weight saving effort??.. In 2 years of owner ship i have never used it...


Ok little update.

Got a bit more done this evening with help from my Grandad (mobil mechanic all his life)

Draining it of oil revealed a rounded sump plug. Got some big grips out and got that off in no time.


Started by taking the cams out to try and get the head off.












Then realised we needed a Tx55 Torque bit to undo the head bolts so we put a stop to the head.

Removed the old exhaust mani and placed the nice new ST170 mani up to check the fit. The only thing that changes is the port shape. Are the ST170 exhaust ports on the head circular? or rounded rectangle like on a zetec?

Anyway that was all good so we then flipped it over and took the sump off to check the crankshaft for wear. The shells look almost new that are in it so very little wear. They will be replaced anyway.


Soon as I can get that torque bit I can wip the head off and asses the situation there.


Then its piston out time and check the bores.

Ok update time.


Got the head off tonight.. Ill let the pics do the talking.









Gave the top a good clean up.





As you can see very little (to no) wear on the bore... there is no lip at the top its really really clean!



Then onto the head...







The crank...



And the flexi pipe from a member on here (maniecruz) thanks mate turned up this morning!




So the upshot of tonight is that a bore is not needed as it is in such good condition...

Some new big end shells and a good clean up should do the trick. Go and order my gaskets this week and sort cleaning everything now

Ok Little update...


Started timing the engine up.. Got the cams set and the pistons at TDC just waiting for some sealant for the end caps on the cam carriers.

I have some ARP con rod bolts on order from Big Will so they should be here soon

Got this is the post...






Then gave her a quick wash and wax...











Excuse the dirty wheels...

UPDATE...

Torqued up all the cam carriers.

Got it all timed and torqued up.

New water pump is in...



Got the rocker cover back on and started cleaning the outside ready for a lick of paint on saturday.






Just waiting on a sump gasket and ARP rod bolts.

UPDATE...

I managed to slap some paint on the block to tidy it up a bit..


Needs a second coat (and i need to do the sump pan too so that will be todays bit..








Also sorted a gearbox and powersteering pipes for £80 which was a result! should be pickingthem up monday!

UPDATE TIME...

Popped back to the workshop tonight to try and sell the old mondie gearbox to some guy on ebay. Turns out he wants a different one.. So no sale..


Anyway..


New ARP Rod Bolts arrived today from BigWill:


New (to me) MTX75 Focus Box after a good clean up:




Finished Painted Block:




Sump:


And oil breather:


And the box full of new goodies!



Got some Gearbox oil seals and Exhaust Gaskets on order from tezza so they should be in the box of bits soon too Should be getting all the bottom end done up on thursday night...


Tonights update...

Not much done tonight as my Grandad was taken to hospital and I had a very minor "DING"in the car ;( . So was kind of bummed out. Tought I would take my mind off things by doing some work on the engine.


So...


This was my bargain exhaust from the bay of E cost me a grand total of £50









I think youll agree its in dam good nick (even still got the ford sticker on it) and it was a right laugh trying to squeeze it into a 3 dr

Then finished off some bits like the oil breather...


Then bolted it on...


Painted the mid cambelt / engine mount cover (cant really see that it is infact black it in the pic)...



Got some of the mounts cleaned and bolted on...



Finally I started work on the inlet manifold but called it a night so ill save all that for the weekend.


The car is looking very eager to have its new engine put in (so am I)


right another little update for you lot.


Went to fit the ARP Con Rod Bolts today......Wrong ones.... Turns out the ones i have are probably for an ST170.... So Should have the right ones by Monday/Tuesday.

As you can see (Left is the ARP bolt, right is the Standard one ):


Then got the inlet manifold on after a good clean out..




Also got the alternator on:



Then bolted the power steering pump back on (I have a question about this but ill post it up in the engine section):


Painted a little bracket off the sump:



Got the A/C pump bracket on (A/C pump needs a right good clean):




but im wating to put the sump on before that can all be bolted up..


Tonights Update...

Picked up my engine mounts tonight (£15 for the lot)



Gave them a good clean in preparation of fitting...




Then gave some other bits like the coil pack bracket a good clean up.

And then test fitted the manifold....











Now i know i need an ST170 Dipstick and tube :twisted:



Thanks for looking.... Ill keep this updated

Big Will_

Tom - did the replacement rod bolts arrive today mate?

Also - ST170 dipstick tube - you're as well buying brand new from Ford, they're about £15 if that!

I spent ages hunting for one second hand and they were all rusty and £10 lol.

Keep going mate - it's a great learning curve

TomEbbs

Thanks mate... Nope no arrivals yet in the post... But i suspect it will be tomorrow..

Yours are all packaged up ready to go

Yehh im going to get one from ford... Its hastle otherwise..

Big Will_

Keep an eye on the post mate - they've definitely gone!

I've got the FINIS for the dipstick tube too if you need it

TomEbbs

Nothing in the post today..

Ive got a dipstick tube on order now anyway £14.22 with club discount. Are the dipsticks the same length...?

Big Will_

Strange... I double checked they'd left for you and was told they had... Let me get a tracking number and chase from there!

The actual dipsticks themselves are yes, just the tubes that are a different shape

TomEbbs

cool nice one mate.

Many thanks.

TomEbbs

Decat pipe arrived this morning...


Japspeed as well... thought it was a budget one.... result.

TomEbbs

Righty oH...

This mornings work... I got up early (from me on a saturday 8.00am is early) so i could crack on.

First on the agenda was to fit the freshly supplied ARP Con Rod Bolts from Big_Will. They fitted a charm So thanks will. Greased and torqued them up.

Old Bolts:


New Bolts!:


Next was to fit the lower crankcase. Popped the gasket on and put it on. Torqued up the 10 bolts:




Put the oil pickup pipe in and a new gasket.


Next was to put the sump pan on. Put the sealant all round the edging and all round the bolt holes. Then popped the sump on and tightened:




Also put some of the sump magnets on.

Got the new oil filter on.

Got some new plugs in.

Got the A/C pump back on (one of 2 that I have so im unsure which to use yet)

Then got the exhaust manifold on:







So a good day today... got everything done alot quicker that i thought


Enjoy!

Glenn_

iTrader: (1)

Top project mate.Have you got the wiring loom and ecu for the 2ltr engine.

TomEbbs

Yeh mate i have a complete early (1999) focus 2.0 wiring loom. After much digging about i have found out that most of the 1.6's loom is the same so i only have to change about a metre.. Which is a bonus!

woolford

good work fella.

TomEbbs

Thanks mate...

Update time....

First off was to show the fitted oil seals (tapes there to stop grit from getting in):




And new thrust bearing:


Clean Gearbox:


Got the flywheel all torqued up (and found a clutch alightment tool :P ):


Mr Engine meet Mrs Gearbox...... :P :











Also got the fuel lines cleaned and on. and got the starter motor on.

Enjoy and stay safe!

TomEbbs

Just bought one of these for the throttle body to the MAF sensor.

Cost me £14...



And this for my MAF to the Pipercross...




Once ive got the jubilee clips total cost will be £30 for the lot... Thats better than £77 from samco

All blue of course...

TomEbbs

OK UPDATE......

The silicone hoses arrived this morning..




Just waiting on some nice stainless steel clips to arrive in the post... I also need to cut them down a bit but that will be done when its all in


I also has the ST170 dipstick and idler to put on... Which also meant the 170 heat shield can go on...



Nice shiny new idler...



I then popped round to my mates house to see the hose placement and locations on his 2.0. Got plenty of snaps as reference...


Came back and painted the off side driveshaft bearing holder.





Enjoy!

TomEbbs

Cleaned and painted drive shafts:






Painted shaft bearing holder..



The tin of hammorite has taken a beating the last few weeks :S

Zetecfiesta

looking good!!

TomEbbs

Thanks mate

COLEYST200

iTrader: (3)

so when is it going in mate

TomEbbs

Monday is d-day so updates and pics will follow!

TomEbbs

Ok engine swap update....


Day 1:



Me and my grandad started at 8.20am to get cracking on the car. Got the front end off in a few hours.






EXCUSE THE BLURRY NESS I GOT OIL ON MY PHONE CAMERA :S





Once everything was unplugged and what not we got the car inside and started the serious work:



Made sure everything was unplugged and disconnected (making sure to mark anything special) Also removed the driveshafts.

Engine was then lifted out and the car rolled back outside.



Think i need a new AC rad lol...





Thats the 1600 in the air on the winch. Its now on the floor with the 2.0 ready and primed.


Tomorrows task is to get the offside hub off to removed a stubburn ball joint bolt (and replace with a new part from ford) sort out the new 2.0 ecu and wiring and generally clean up all areas of the bay ready for the new install.

TomEbbs

Okie dokie!



Todays progress was exactly as expected.

Went and bought some bolts from ford and picked up a new offside wishbone (came to a grand total of £29 with all the bushes) from euro car parts so that was good.

My grandad bolted all those on.


While i sorted the wiring and gear cables...

Can anyone tell me what this black box is with the red button on top? Is it a fuel pump reset?


Anyway only a few pics... Nothing major...

Bit of ECU wiring...



2.0 gearcables installed



So that was that for today. Wirings in and the 2.0 ECU is in. Gear cables are in. New drop links are on along with a new wishbone.





Tomorrow is 1.6 exhaust off and the ST170 one put on (cat back only) then we will see about putting the engine in


Enjoy!

ByronMk2

Looking good dude , car is going to be sweeet, cant wait you got to take me for a blast when its done .

TomEbbs

Once its all ran in then yeh i can take you for a quick blast

TomEbbs

DAY 3...and some very positive progress!

Started the day by removing the rest of the 1.6 exhaust system... turned out to be a right ar*e ache because everything was solid. Got it off eventually and replaced with the ST170 system...







Then finished up the last bit of interior wiring and putting the interior back together.









Then the guy from DHL dropped off my ST170 power steering pipe. So we got that all bolted on.



Then things were looking like this....









We then started to move the car and engine closer together until this happened





Then by the end of todays stint things were looking like this..







Gear cables are connected (and the gearbox is operating which is nice) Started connecting the loom and hoses (not to each other mind)

So good progress today. Trying to take as many pics as i can. Hope its an enjoyable read...


Tom

TomEbbs

Thanks for the comments guys! I cannot wait to fire it (which should be in the morning)

Ok update time..


Painted driveshafts in..





Checked the position of the decat pipe Can anyone tell me if the lambda sensor wiring goes down the front of the back on the engine on a 2.0?



Then sorted the last few wiring bits out using the trusty haynes manual diagrams... trouble is with a second hand loom that parts can be missing or hidden. Thats all sorted now.



Had to pop to ford to get a power steering union for the new hose.......I was thinking maybe £3.........Ohhh no.....£11.48 :O WTF but oh well i need it and they have it. Thats now on the car..

Got all the hoses connected and topped up the coolant and power steering fluid.







Tommorows list...
- Sort a problem with the inlet vacuum tomorrow (we now have the parts to do this so thats not a problem)
- Pop the decat pipe in with all the gaskets.
- Engine and gearbox oil.


THEN WE CAN TURN HER OVER.....

TomEbbs

So basically yesterday was spent making a 6mm plate to fit between the manifold flange and the decat pipe flange. The bend in the decat just (and i mean it was barly nothing) touched the driveshaft. After a few hours machining and grinding the plate was finished. Had to pop to ford to pick up another 170 gasket. Bolted it all on and it fits perfect. Plugged in the lambda sensor and that was all done.







Then we moved onto the rest. Filled the gearbox with oil...it took ages to fill too..... but we got there in the end. Got the engine filled up.
Then it was run time......... Popped the key in and turned once.... thankfully the imobiliser was playing ball (as i thought this might be a problem area) and all the lights came on... Thinks were looking up. 2nd click and the fuel pump sounded which was also a very good sign.........3rd click she held on the starter motor for about 10 seconds then fired! I was extattic. There are a few problems at the moment. The fans are on pretty much from startup....anyone know why this would be?? And also i have a battery light on even tho my volt gauge is showing a good charge (13.7v at idle and 14.1v when the fans cut in)


Ive got to pop back to the workshop today to put the bumpers back on and tidy some bits up then its time for a drive i think. Ill pop all the pics up later on. Thanks for all the support guys...

Ok this is how shes is sitting now..... All finished...
Just need to sort out the fans (in need of a cylinder head temp sensor)




Enjoy!

HockeyNomad

Good work,

what happened to the hoses you ordered for the intake pipe?, looked like a good idea!

nice to see you managed to get this project turned round so quickly mate,

TomEbbs

the intake piping was a good idea but was a bad fit in regards to the corner of the rocker cover, the fuse box and the bonnet when its shut.... So i ditched it. Ill use it for something else.


Thanks for the comments mate.

DannyP

Been a joy to read, good job dude.

Doajim

very interesting m8

dont suppose you could pm me what shafts you used and indeas on the wirering and so on my 1.6 just gave up and my 2.1 zetec turbo not built yet so may just go get a 2.0 the now to keep me going??

Focus333

Did you only need the ECU or did the keys etc need changing too?
Old threat I know but having an idle issue with my 1.8 - 2.0 conversion!

Straight_4_N/a

you need to cut the elbow down abit (iirc you need to take half the height off it), ive done it on my 1.8 focus but make sure you cut it straight.

Red16

Good work, looks a nice car, always good to see people doing stuff themselves.

TomEbbs

Thanks for the comments guys,

Focus333 - I needed the 2.0 ECU and Transponder for the key. I actually use the master 1.6 key with a 2.0 transponder and it works just fine


You'll be happy to know I still have the car even after all this time.. The conversion was done at 118,000 miles and Ive just rolled onto 143,000 and she is still thundering on. Just in need of some front wishbones at the moment. Still a joy to drive.

Focus333

Nice! Well I sorted my idle problem, altered the throttle position as a temp fix, hopefully getting it mapped this weekend! With my piper cam, manifold, timing advancement and other little tweaks looking at 165-70whp