Jobe

Hi all,

I have an interesting project that ill soon be undertaking.
I have a near mint 2003 mk6 fiesta finesse and have been given a mechanially sound and cosmetically battered 2001 mk1 1800 focus zetec.
I am really keen to put the zetec in my fiesta. I know im likely to hear "why not just put an st150 engine in it". Answer is, id rather do something a bit different.
Theres virtually no info online about this conversion even though some people seem to have done it, so im trying to put together a thread to help myself and others who fancy the same conversion
What engine mount can be used?
Is the standard IB5 gearbox ok to use and does it bolt straight onto a zetec?
Any other info you guys could add to the thread would be greatly appreciated.

Thanks in advance

Adder

I don't think I would bother with the st 150 engine either. I've not done that convention your thinking about but I've just just mounted an id5 box onto 1800 silver top Zetec, and used a Mondeo flywheel if that's a start for you.

Adder

Jobe

It certainly is a start. Thanks pal.
I assume theres no difference in silver top and black top as far as gearboxes go?
Why the mondeo fly wheel? Is the 1800 zetec dual mass?

Adder

The 1800 fly fits in the bell housing and is just a normal set up. the 2.0 won't. It's to big. I'm sure can use an cvh efi fly wheel you just need to make the mounting holes bigger . I think also there a bit lighter

Adder

Jobe

Righto. Quick update on the progress so far. 1800 zetec, gearbox, driveshafts, wiring loom, ecu, key and transponder and mounts are all removed from the focus. The engine will be having a tarting up and new seals, gaskets and belts fitted. I removed the top engine mount from the fiesta today to see if i can mix and match both fiesta and focus mounts. I can use the mount plate from the fiesta to bolt to the fiesta chassis, and the focus rubber bolts into the plate. Only slight modification to the mount i done was to open the hole about 1mm for the focus rubber. Obviously until the engine is in, i dont know for sure that its going to work, although i cant see why it wont.
​​​​

RichieST

iTrader: (2)

Good luck! You will probably also need the dash clocks and other bits of interior loom. The clocks run direct from the ecu so probably aren't compatible with each other.

Jobe

Thank Richie. I have the clocks too but i didnt think of the interior loom. Grrr. Focus has been scrapped now. Oh well. Theres always ebay. Would i need to keep and run both ECU's?
Update as of today. The A9B engine has been removed from the fiesta and is up for sale. As far as i can tell the focus and fiesta both use the IB5 gearbox. The starter positions on the belhousings are different though, so since the focus gearbox is a bit grindy, i figured i could replace the fiesta bellhousing with the focus one, keeping the focus starter position. Would this be feasible? Im not after big power so im happy that the fiesta box will be up to the power increase from the zetec.
​​​

Jobe

Thanks Richie. I have the clocks but didnt get any of the loom. Oh well, theres always ebay.

big_wasa

It's just a case of matching up the the lives, earths and sensors ect.

Both dash pods would get sensor data down the bus network and I would hazard a guess being so close in age it will work fine.

The focus is a 60 pin eecv ecu.



"Shorty". List

Enjoy



Pin No-Colour-Function
1-Red-Battery
2--
3-White/blue-Vehicle speed sensor (VSS)
4-White/purple-Audio/cruise/trip
5-White/green-Immobiliser control module
6-White/red-Air con
7-White/purple-Cylinder head temp (CHT)
8-Green/black-Fuel pump relay
9-Purple/blue-Mass air flow (MAF)
10-Green/yellow-Air con
11--
12-Black/white-Injector 1
13-Black/blue-Engine coolant blower motor relay 1
14-Black/orange-Injector 4
15-Black/yellow-Injector 2
16-Black/yellow-Earth
17-Orange/black-Data link connector
18-Blue/black-Data link connector
19-Grey/orange-Data link connector
20-Black-Earth
21-Black/yellow-Idle air control (IAC)
22-Black/blue-Evaporative emissions (EVAP)
23--
24-White/purple-Camshaft position sensor (CMP)
25-White/purple-Intake air temp (IAT)
26-Yellow-Throttle position (TP)
27--
28-White-Power steering pressure(PSP)
29--
30-Brown/white-Camshaft position sensor (CMP)
31-Black/white-Engine coolant blower motor relay 2 AC
32-Black/red-Starter motor relay
33-Black/yellow-Heated oxygen sensor (HO2S)1
34-Black/blue-Injector 3
35--
36--
37-Green/yellow-Engine control relay
38-Grey/orange-Immobiliser control module
39-Black/orange-Immobiliser LED
40-Black/yellow-Earth
41-Blue-Alternator
42--
43-White-Clutch pedal position (CPP)
44-White-Heated oxygen sensor (HO2S)1
45-Grey-Alternator
46-Brown-CPP, CHT, HO2S, IAT, TP
47-White-Throttle position sensor (TP)
48-White/red-Heated oxygen sensor (HO2S)2
49--
50-White/blue-Mass air flow (MAF)
51-Black/blue-Heated oxygen sensor (HO2S)2
52-Black/green-Ignition aux circuits relay
53-Black/blue-Fuel pump relay
54-Black/yellow-AC compressor clutch relay
55-Brown/red-Crankshaft position (CKP)
56-White/red-Crankshaft position (CKP)
57-Green/yellow-Engine control relay
58-Black/red-Ignition coil
59-Black green-Ignition coil
60-Black/yellow-Earth


I've done a 2000 ish fiesta 1.6 Zetec Se loom for a mate, putting it in a Kitcar. This one is a 60 pin with pre and post cat O2 sensor and knock control. Compare the ecu codes.



Ford Fiesta 1.6 Sport Zetec SE Ecu code CHCA

60Pin ecu

1)—Orange—12v perm live for ecu Memory.
2)—Black—Knock sensor.
3)—White/blue—Vss speed sensor plug pin 2.
4)--White/black—Tacho output.
5)--White/green—Immobilizer aerial (Pats).
6)—Black/blue—Ac high pressure switch.
7)—Black—Engine coolant temperature sensor (Ect).
8)—Purple/black—Fuel pump monitor.
9)—Brown/blue—Mass air flow meter (Maf).
10)—Purple/blue—Ac.
11)—Black/orange—Canister purge valve.
12)—Black—Injector 1.
13)—Black/blue—Engine fan relay.
14)—Black—Injector 4.
15)—Black—Injector 2.
16)—Black/yellow—Chassis earth.
17)—White—Data link connector (Dlc) pin 13.
18)—Blue/white—Data link connector (Dlc) pin 10.
19)—Grey/purple—Data link connector (Dlc) pin 2.
20)—Black—Chassis earth separate from pins 16+40+60.
21)—Black—Idle control valve.
22)--.
23)—Black—Knock sensor.
24)—Black—Cam position sensor pin1.
25)—White/purple—Air temperature sensor (Act).
26)—Black—Throttle position sensor (Tps) 5v (yellow).
27)--
28)—Black/yellow—Power steering pressure.
29)--
30)—Black—Cam position sensor pin2.
31)—Black/white—Hi speed fan relay.
32)—Black/blue—Starter motor inhibit relay.
33)—Black/Yellow—Pre cat O2 sensor.
34)—Black—Injector 3.
35)—White—Instrument cluster.
36)—White/red—Data link connector pin7.
37)—Purple/yellow—Switched 12v.
38)—Grey/orange—Immobilizer aerial (Pats).
39)—Black/orange—Immobilizer status Led.
40)—Black/yellow—Chassis earth.
41)--
42)--
43)—Brown/white—Clutch pedal position switch.
44)—White—Pre cat O2 sensor.
45)—Black—Alternator.
46)—Brown/red—Sensor common.
47)—Black__Throttle position sensor.
48)—White/red—Post cat O2 sensor.
49)--
50)—White/Blue—Mass air flow meter.
51)—Black/blue—Post cat O2 sensor.
52)—Black/blue—Instrument cluster Mil.
53)—Black/blue—Fuel pump relay switched earth.
54)—Black/yellow—Ac.
55)—Black—Crank position sensor (Cps) pin 2.
56)—Black—Crank position sensor (Cps) pin 1.
57)—Purple/yellow—switched 12v.
58)—Black/orange—Coil pin 1.
59)—Black/green—Coil pin 3.
60)—Black/yellow—Chassis earth.

big_wasa

Re your first post.

The ib5 from the iron block 1.3 ka will bolt up. The ib5 from the alloy block 1.25 1.6 1.7 will Not bolt up.

What box is on the focus ? I know the 2.0 is mtx75 and the st170 is the getrag 6 speed.

Jobe

Thanks for the help big wasa. Such a huge help. The gearboxes im working with are both IB5 ( im told the best way to tell is that the gear selector cables are round the front of the box).
The gears in the focus box are chewed so im in the process of swapping the focus bellhousing onto.the fiesta box. That way the zetec starter position is ine correct place.
​​

Jobe

Thanks for the help big wasa. Such a huge help. The gearboxes im working with are both IB5 ( im told the best way to tell is that the gear selector cables are round the front of the box).
The gears in the focus box are chewed so im in the process of swapping the focus bellhousing onto.the fiesta box. That way the zetec starter position is ine correct place.
​​

Jobe

Hi big wasa. Wow. Thats going to be a huge help. Thanks for that.
Bothy gearboxes are ib5. Im told the ib5s are identified if the gear selector cables are at the front.
The gears in the focus box grind. I dont know why, it was already done when i gave my step mum scrap value, apparently.
My thought was to swap the focus bellhousing onto the fiesta box, but my experience of gearboxes is limited to army landrovers. I assumed the bell housing would just unbolt and come off. Instead it seems tied to its internals somehow. Little bit out of my league. How do i remove it? Or ultimately would i be wiser to get hold of another focus gearbox with rear starter position and just bolt that straight up? Cheers for all your advice buddy. Its really appreciated.

Jobe

Blacktop zetec fitted.
Hi peeps.
Righto, time for ab update. I have managed to get the focua 1.8 zetec blacktop and gearbox into the mk6 fiesta.
So far, the alterations have been as follows. Emgine mount plate from the fiesta mk6 needs to be mated to the top half of the focus.engine mount.
The top gearbox mount on the focus gearbox needs to be swapped for the one from the fiesta mount. Direct swap
At the moment i have a minor issue.with the lower gearbox mount not lining up with its mounting point. I replaced the focus one with the fiesta one. Maybe i should use the focus one. Ill try it and update that detail.
But dimensionally, the focus mk1 blacktop does fit the mk6 fiesta.
​​​​​
​​​​​
​​

RichieST

iTrader: (2)

Good stuff mate keep us updated on how you get on

Jobe

Engine sitting at an angle. Hopefully because lower gearbox mount isnt fitted yet
Lower gearbox mount not lined up. Its actually sits level with the left prong.


Gearbox selector cables have been fitted to the 1.8 gearbox, and all gears seem to select fine.
The inlet manifold is on but i dont think theres enough room for the induction pipe. Might have to get the efi over cam cover inlet from the fiesta rs, although id rather stay as true to the focus as i can. The lower gearbox mount doesnt line up so i may have to remove the sub frame mounting point, move it over and weld or bolt it back on. The engine is sitting at a bit of a jonty angle and rocks. I assume this is because the lower gearbox mount isnt fitted yet.
i also have to do something about the power steering pump, as theres not enough room for the focus one doesnt fit. May have to try and use the fiesta one if i can. Definatley starting to come up against some issues now.

Jobe

Today the focus power steering pump went in, as did the focus alternator and its mount. Drive belt in and tensioned.
Removed the fiesta throttle cable because its a different design to the focus one. So installed the focus throttle cable. It works but my throttle is slightly open at rest so need to make some adjustments. Can anyone tell me what this is for in the photo please? Its on the focus throttle cable. I assume its an adjuster? All in all, a successful day i think Whats this?

​​​

Jobe

I went to install the transponder ring bit noticed that the connections are different. If i got a focus one, would i be able to just cut this connector off and solder a focus ome in its place? Or is it not as simple as that? Fiesta transponder ring connector
One on the left is focus

Jobe

Ive been messinv around with the engine mount to get the engine to sit level. It turns out i needed to use 2 inch spacers between the mount and the engine and longer high tensile m12 bolts. This 2 inch engine drop appears to have lined up the gearbox to the fiesta mount point. Just waiting for a new lower gearbox mount to arrive. 2 inch spacers i made from 30mm solid steel bar. Turned them down to 20mm with 12.5mm inside diameter. Perfect for the m12 bolts
New m12 engine bolts fitted before spacers to get an idea of how long my spacers needed to be

Engines level 😊

Jobe

New lower gearbox mount turned up today. Thanks to the 2 inch drop from the engine mount, the gearbox mount lines up. Its in and solid as a rock. New gearbox mount. All lined up now thanks to the 2 inch drop from the engine mount

big_wasa

Any chance of some pics of how much room you have between engine and rad ?

Turbo turbo turbo all on the focus rs ecu.

big_wasa

're the pats aerial. Try the festa if it works great, if not just cut the plug of and use the other.

There is a difference in frequency between blacktop and silver top 2.0 zetec but I don't know about the the fiesta. Ect.

Jobe

Hopefully this angle gives you an idea of how much room there is for a turbo
Maybe my hand will give you a better idea.

Jobe

Definately going to have a problem with the wiring. Its certainly not my forte.

slammedorion

Slim line fans and a turbo will fit easy in there

big_wasa

Yep loads of room. I will now need to spend ages on eBay looking for a cheap one.

You will be amazed how easy the wiring is if you do it in small stages.

Jobe

I hope the wiring will be easy. Its the bit ive been dreading the most.
i have the engine loom, ecu, key and transponder ring. Am i going to need both ecus running? I seem to remember hearing that the dash clocks run off the fiestas ecu.
Obviously id prefer to run it all off the focus ecu if theres a way to achieve this without hving to get an interior loom and shoehorn focus clocks into the fiesta.

Also, would the 1800 zetec run a small turbo on low boost with stock internals? Not looking for massive power, just a subtle kick up its arse when the mood takes me

​​​​​​


​​​​

big_wasa

Are the ecu's the same type ?

The mk5 ecu is the older ford style. The St150 had what looks like a Mazda ecu. If yours is the old ford style ecu then you should just need the focus ecu.
"Should" that's not a guarantee. I normally like to do the conversion and play with it as little before singing its merits.

The ecu controls the AC other than the engine but that's about it.

How the engine ecu will get on talking to the Gems, and and dash you will have to see.

I think it will work.

There are mappers that say a 1.8 will produce nearly the same output as a 2.0. It's all in the mapping to make sure there is no det or massive boost spikes.

I do it differently . I build the engine to match the mapping as its cheap and quickly and plug and play.

If you can get your focus ecu to work then the focus Rs ecu will work. Drop a 2.0 in and away you go.

Jobe

To be honest, i have no idea if its the "old" style.
Been looking at my focus ECU plug today and cross referencing it with the information above. I think I have some of the wiring sussed, but I am getting confused with what wires from the focus plug go to which wires on the fiesta loom. I'm torn between whether I need to make a kind of focus/fiesta hybrid loom, utilizing whats needed from each loom, or use the entire focus loom. Wiring really isn't my thing. Really struggling with this part. Would really love some guidance please guys.

Jobe

My brain is frazzled. I've been trying to match up the wiring from the focus ecu plug to the fiesta loom. I have no real way of knowing what I'm doing. The only method I have is to simply match up the colours, but I have lots of duplicate colours.
There's a few black/yellow wires and a few white wires on the focus plug and fiesta loom. No idea what any of them are for or whether i can get them wired up wrong. I'm so confused right now. Please help 😕

Jobe

Big wasa. Heres my ecus. I dong know if its the old style or not. Was hoping youd know. 😉




This is the fiestas ecu.

big_wasa

Yep your focus is the old style and the festa is the new style. Your on your own on the festa side of things as I've never done the Siemens.

Depending on what it does will depend on weather you need to swap out or piggy back onto.

You should be able to work out if the festa ecu does "everything" or just the engine and a few odds and sods.

Juicy

Crazy that I've stumbled across this thread.
been researching for a while now and I'm almost ready to start the conversion myself.
I have a 03 plate fiesta and engine mount to suit the 1.8 engine.
only difference is I was going to strip whole fiesta and just put focus clocks and dash loom into fez.
as like you my electrical knowledge is slim so I was planning on cutting and twisting (done properly) all lights and what ever else I could to work with fiesta stuff.

Jobe

Im starting to wonder if i should of done the same thing. Ive been staring at both looms for nearly two days now, and im none the wiser. I bit the bullet and cut the ecu plugs off both looms (spur of the moment and will likely regret it).
​​​​​My theory is with both cars being close in age and of the same brand, the wire colours should be consistant. No idea if thats correct mind, im at a loss at the moment and that is pretty much my only move at the moment.

Juicy

I'd cut your losses.
in 2 days you could fit focus engine and dash loom with focus clocks, and wire basic lights in for now.
Just cut and twist the wires form focus light to fiesta same light and you use all fiesta plugs.
That was my plan. Brake lights and indicators and go from there.
Then make adjustments to fiesta dash to fit around focus clocks.
not perfect but makes it alot easier, just like a focus car in a fiesta she'll, literally

big_wasa

Cutting both plugs of is a bit drastic.

Rowe

simple but more costly thing to do would retain the original fiesta harnesses

Then just buy a plug'n'play ecu and loom for a zetec and have that working the engine.

Juicy

like a standalone ecu? Omex or megasquirt are cheaper but by far still not cheap

Rowe

exaxtly like a stand-alone. Me221 or a KMS is worth considering.

The big problem is that he’s butchered the plug off the standard loom.
Persoanlly, id refit another standard loom then save up for stand-alone (as I’m not good with electrics)

Juicy

Ye but the basic spark, fuel and air ecu is 300.
omex 800 for a full loom like dash buttons and so on is about 800.
I too would get another standard loom tho