Hi i got the universal 2.25" pipe kit and intercooler for 130 all in off ebay from tuningpartsbay. Buy it now it comes to about 170 i think but i got mine in auctions from the same seller. The Si bumper are a big improvement over the quartz thin black bumpers so go for it. Im sure you could keep the tow bar with a bit of cutting if its needed.
As for the swap it theres are a few clearance issues
1) alternator on the TD is on the back, for the fiesta i used my 1.8D atlernator and bracket to put it on the front under the fuel pump. The alternator pulley needs changing as it fouls the chassis so the 1.8D fiesta one is needed.
2) The oil filter will stop you getting the engine in right so it needs to be put on after the engine is in. Not too difficult to get at from underneath.
3)The injection fuel pump needs to be attacked with a grinder and you need to carefully remove the security shield covering the immobilizer solenoid so it can be either swapped for the one on the old pump or hotwired to open with an ignition live feed.
4)The brake servo and master cylinder get in the way of the turbo compressor inlet and outlet so it needs to be moved 10cm to the right and the servo linkage cut and extended
5)Cooling pipes will need to be custom jobbied by urself to fit the fiesta. I went to a scrap yard and got one of a td and straight d and combined the two where needed to get it working.
6)fuel lines may need to be adapted a bit. I used the mondeo ones that look neater than the fiesta so they went left around the engine timing cover and around the back.
7) the exhaust needs to be changed for a 2" one again a custom job to get it to fit the fiesta neatly.
8) intercooler... some come without but if you want one the top mount may not fit in the fiesta i dont know as i fitted a FMIC so you could either buy a FMIC or the standard top mount or without. FMIC approved by myself tho for plenty more power and potential with a bit of tuning.
If your 1.8 lump is good and has low miles you could just buy the bits i mentioned above, fuel pump, fuel filter...optional, coolant and fuel pipes, turbo, inlet and exhaust manifolds.
The diesel dump valve, i know theres no point on a diesel really except for noise but i love the noise havent bothered getting it working yet. It is just a cheap ebay one, i need to get the vacuum solenoid valve and microswitch to get it working, which i didnt know when i bought it. I know this one will make the pssshhh sound, how do i get the turbo chatter sound is that a recirulating dump valve?
It doesnt have the Audi RS badge anyway,thats how it used to look before i went a bit mad with the fibreglass. ive done plenty of bodywork since making a wide arches to make clearance for alloys, skirts, smooth boot, escort rs vents and subtle bad boy bonnet, Cosworth style front lip on the Si bumper. And plate relocated to rear bumper, Roof luggage rack lines filled in, smaller mirrors and Rs style spoiler made a bit bigger. Most of the work is doen but its rough, just needs smoothing out and painted
Its a great improvement of the standard 1.8lump!
I checked the direction the fan was blowing, it was going the right way thanks for that suggestion. I figured it must be the Head Gasket Failure so i took the head of the car and the gasket was pretty bad. Usually Head Gasket Failure is quite serious but as i have a spare engine to get parts off its only an inconvenience to me. Il use my 1.8D lump head and fit the Td valves, they are exactly the same but i think theyl be in better conditon than my old engine. Im just about to go out now and get started stripping the valves from the 1.8TD head, then il rebuild using the 1.8D head. I dont have a valve spring compressor but i used a 27mm piece from my socket set to remove the valves by applying pressure to the spring it allows the 2 metal keepers to pop out. Its a bit tricky sometimes but thay all came out ok. I hope they go back in ok or i may have to buy the proper tool!Il make sure to take a few pics of this too to go in the guide....that i will get around to eventually! lol
Thanks for all the comments and suggestions! much appreciated!