I'm afraid I can't really help on the eletrical side of this....

However, did you know the RS2000 uses a different gearbox to your 1.6?

You have 2 options.

The common way is to change to the larger RS2000 gearbox (MTX75) and use the RS2000 driveshafts (1inch, as opposed to your current 17mm), RS2000 hubs, etc etc... I also beleive the subframe carries an extra mount for the rear of the gearbox!

Option 2, and I've never heard this done... is to use the 220mm flywheel from your original 1.6, which will enable you to use your current gearbox and drivetrain!!

It will have no problems with 150bhp. I didn't have any with 165bhp on a throttle bodied zetec, and many people have run higher bhps still.

Have a look at Escort Evolution too mate. Lots of people have done engine swaps there, and you should get an answer with regards to the loom and ECU

Ralph.