Okay - bear with me on this as I know there have been discussions in the past about such modifications.

I've sourced a complete LHD Ford Focus ST170 cheaply with a decent 16 Valve engine which I plan to eventually use in my 1991 Ford Sierra 8V.

The plan would include a full transplant of the engine, ecu, wiring looms etc and integrate these components into the current LHD Ford Sierra; such as using the current Sierra dashboard switches for lights, and for electric windows etc to name a few parts.

I do not want to go with the likes of Carbs or Megasquirt options as would rather use the complete wiring system from the MK 1 FF St170, including air intake system.

What I would like to know is whether or not the 300mm front discs, brake calipers, caliper carriers as standard on the ST170 (and calipers) are transferable to the ford sierra system. If not, what is the best system to consider when upgrading the normal 2.0i (125bhp) sierra brake system?

As the car is currently running well, this is something that I only plan to do some stage in the future.

I presume the exhaust manifold from the sierra is either compatible or perhaps requires further modification to make the engine align with the current sierra exhaust system.

With regards to suspension set-up (the car is my daily) I'm looking at getting rid of the standard 'feels like a boat on a stormy sea suspension as I like to go to the Alps (I'm based in Munich) when the weather is decent so I'm looking for more stability rather than the excess body roll the car currently exhibits when introduced to mild corners (makes it a bit hairy at times).

Cheers lads/ladies

Bren.

 

Cool project, I started to do one years ago but cut it loose due to no space.

You don’t need to transplant all the full looms. Chop up the ecu loom add in some plugs from the sub looms and build the loom as a stand alone unit.

If you have the 8v twink then you have the Mt75. Don’t try and use the Dual mass flywheel, the clutch won’t work anyway. For a daily the 2.0 Zetec flywheel and clutch work fine. Due to the more compact fwd flywheel and clutch you need either a longer thrust bearing, look at Westfield. Or extend the clutch fork pivot pin. Look at Kitspares / Gbs. It’s pretty easy to make one and it needs to be around 20mm longer than stock.

sump. It will need changing. All sorts of options here. I personally hate the 1.8cvh sump but it is an option.

Thermostat housing, this won’t fit against the bulkhead and most opt for a water rail.

exhaust manifold. The st has a thick stainless one as standard. These clean up and can be chopped up and weld up nicely..

 

I forgot to say, the limiting factor of using the Oem st170 ecu rwd is you need the inlet manifold. with out it it will make less power than a stock Zetec.

Others have got around this by flipping the manifold upside down on the joiners and making up a new bracket.

 

 

thanks a million for your advice. I’ve another project currently being sorted (Volvo 850 AWD - V70R 300bhp hybrid engine rebuild) back home in Ireland so plan is to use the Volvo in Germany while the Sierra gets sorted out back home with a mechanic mate of mine (he’s sorting out the Volvo engine rebuild at the moment) and then bring that back to Germany once ready. May be in touch with you at a later date if you are free to answer possible future questions that may crop up as that build progresses such as modifying the wiring to the ecu etc (that would be really helpful).

Spoiler to be replaced


I’ve managed to meet up with a Ford nut around 1.5hrs west of Munich who has supplied me with Good set of front Cosworth Recaro seats for only €80.00 and a nice RS spoiler for €20.00 to replace the sagging spoiler on my own car.

So I’ve got those ready to go to a reupholster here in Munich to stitch the Ghia Apollo fabric onto the Recaros to keep the interior as stock as possible but with more comfortable seats.

 

Okay been trying to figure out the in-and-outs of engine transplants here in Germany and it's proving a rather complex process. Are there any Germans who have modified their Fords on this site that could perhaps assist me with trying to figure out the red-tape? I contacted TUV but the only reply was that this engine didn't come as standard with the Ford Sierra (naturally!) and that it would require more effort than worth the financial cost. Price isn't my concern and all i have to go on is that the car would need to be retested (but not with TUV - with another entity whom they won't clearly explain to me).

I'm sure this engine mod has been done in Germany, if so, can someone lend a helpful hand with regards to what i need to do?

I did raise the question of VW Beetles having non-standard 2.5 Flat Fours from Porsches been modified and sticking out from behind in cages but that observation was ignored by the TUV when i challenged why one rule for one marque, and another rule for Ford.

 

Just done a quick google using the term car engine modifications in Germany TUeV and it looks like any modifications from factory need to have a TUeV inspection, who then issue a certificate.

If you're stopped on the road by the Police with mods and without a TUeV certificate for ALL mods, which include wider or narrower tyres / rims then it's a fine.
I believe that the parts fitted usually have to have already had approval, not a problem if you're fitting a same make different engine, but may be a problem if your'e welding up brackets etc.

NOte TUV is the same as U.K Mot, TUeV seems to be the same as IVA (formerly SVA) in the U.K

Online information from TUV seems poor, but if it's anything like DVLA in the U.K, the info is there it's just badly indexed.

It looks like you'll need Individual Approval (same as U.K IVA) called Einzel Fahrzeugabnahme

 

Yes thanks a mill for your reply. The problem is that there seems to be a bit of a reluctance by the person i was in touch with in the TUV to be more forthcoming on what tests are needed, and where i can get them.
I ended up contacting DEKRA today as they have a department dedicated to car tuning in Germany so I'm hoping to get more success from them wrt what i will need to do to make the conversion happen next year following the car repaint job in Croatia.
Still waiting on getting new Apollo fabric to recover the Cosworth recaros from Martrim in Manchester that I have sitting in my storage locker here in German.

Will keep the thread alive with this once i hear more information - if, however, more German based tuners are able to offer further advice on top of the great information from Focusv8 then that would be appreciated.

 

Though I've thought long and hard about doing this conversion, I've bought an ST220.

So despite having all the parts on shrink wrapped on a Europallet for the conversion on the Sierra, I've spent a few thousand over Christmas re-doing the Sierra and with that will keep it as 'Factory'.

Goes for a full respray in the Balkans in June so looking forward to its final piece of the puzzle getting finished then. Into storage it will go then.

Will hold on to the ST170 Conversion for the next while and see if it garners any interest by other parties down the road when these parts (complete conversions) become far and few between.

Think this thread could be closed.