FULL GUIDE: Fitting our 2.0 Zetec Blacktop 190 package into a Fiesta Mk3
From M-Tech Automotive
Tony came to us with his RS1800i Mk3 Fiesta that he uses for track tuition at Castle Combe. He was after more power, within a reasonable budget. For this, we opted on a recon 2.0 Blacktop fitted with Kent SuperSport cams and Jenveys to give approx 195bhp, and something that could handle the thrashing it was due to recieve!
Contents |
Current Engine
Old and New...
After removing the old 1.8 silvertop engine, you can see it here side by side with the 2.0 Blacktop:
Fitting RS1800 Sump
We carried out the spacer mod on the windage tray as per GTI_Toms info (thanks!) and built the engine back up with the RS1800 sump. This is needed to be done as the mondeo exhaust system (and hence sump shape) is different from the Fiesta.
For reference, the spacers are fitted between the bolt head and bearing cap. Height = 19mm, OD = 21mm, ID = 13mm. If anyone needs some we can turn them up....
You will also need to fit the Fiesta pickup pipe, but thats a straight swap. Just use a new gasket...
Flywheel
You must use the RS1800 flywheel, rather than the mondeo clutch, I believe that it is the same as any silvertop 1800 flywheel....
We then removed the standard mondeo 2.0 flywheel and fitted the one from the RS1800. (Remember to use new bolts as they are the stretch type!) Also, fit the CPS from the 1.8 as it is a different length to read the flywheel correctly. We then fitted an uprated RS1800 clutch kit.
The SuperSport Kent FOCUS3 Cams were then fitted to the head, and a new cambelt kit installed. (We are a Kent dealer, so drop us a line if you're after some...)
Running the Water Pump and Alternator
We used an idler pulley and bracket from RetroFord, (under £40 for the whole kit) which means we can run the serpentine mondeo water pump correctly.
Russ (our smelly yet able mechanic) then cut the original alternator/front mount down such that the standard RS1800 alty could be fitted without the front engine mount which normally would foul the Mondeo 2.0 water pump.
Rear (cam pulley end) Engine Mount
After getting our hands on modified rear engine mount (thanks to Si at Si-Tech Racing) we then refitted the engine to the bay. Its an RS Turbo item modifited to fit the blacktop bolt pattern.
Cooling System
Tony won't be running heaters, which means we could simply connect our water pump outlet straight up to the rad. If you are going to be running a heater matric, you will need a T-Piece to feed the matrix. The thermostat outputs for the heater matrix can be simply looped around.
The thermostat housing is removed from the silvertop and fitted to the blacktop engine to retain the factory sensors....
Throttle Bodies
The next step was drilling and tapping the Jenvey inlet manifold to allow fitment of a brake vacuum takeoff for the servo.
