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#128775 - 7th Feb 2006 7:33pm 2.0 Focus Inlet manifold upgrade
Dazza Offline
Forum Master

Registered: 10th Nov 2003
Posts: 2899
Loc: Birkenhead
2.0 Focus Inlet manifold upgrade

Its the 1st of its kind as to my knowledge only about 2 people have done this,
with me being the only to write a guide about it
so its a popular guide to say the least smile

Parts needed:
1.8/2.0 Focus inlet (Both the same),
2 wiringplugs off the focus wiringloom (I have listed which ones in the guide),
Focus inlet bolts,
fuel connectors,
vacuum hose

This guide is for fitting a 2.0 Focus inlet manifold to the 2.0 Mondeo engine
which is in my Fiesta SI. You cant use the Mondeo inlet manifold as it does not
fit between the engine and bulkhead. By using the Focus inlet you gain a
few things such as bigger ports to allow more air in, inlet is made of
plastic so is lighter, ability to use top-fed injectors which are
easier to obtain if seeking more power.

Start by removing the original manifold,
if you compare the two manifolds together you'll see a few differences
so you will need the focus wiringplugs.
Make these changes to your wiringloom.

You will need to keep the old wiringloom and attach it securely
in the enginebay so it wont get caught with engine movement.
You will only need two of the Focus plugs and they are the ISCV plug and
the Throttlebody (TB) plugs as pictured below.

Sensor 			1.6 wiring colours connect to... 	2.0 wiring colours 
ISCV sensor 		Black 					Black/Yellow 
  			Green/Yellow 				Yellow/Brown 
Throttle body (TB) 	Brown 					Brown 
  			Green/Brown 				White 
  			Brown/Black 				Yellow 
Carry out the following changes before fitting as it makes it alot easier.
The inlet is a tight fit and I removed the cam sensor and back engine
liftingeye to allow for more room, just remember to re-fit them again.
The Focus inlet bolts are shorter than the 1.6 ones and need to be used,
I bought brand new ones from Ford for 2.70 so there not expensive if you dont have them.

The fuel rail has to be slightly modified by the fact that only one of
the fuel lines will reach. You will need to use some fuel line and
connect it from the regulator then neatly run it under the manifold
to its fuel supply *NOTE* Make sure you use jubileeclips to maintain
a tight seal. Pictures below of the added fuel pipe.
Connect the new fuel pipe to the RED fuel connector (Return pipe),
and the other pipe to the WHITE fuel connector (Feed)

The Crankcase breather runs back into the inlet to re-use harmful gases
and it also helps atomise the fuel mixture by helping it burn better
when the engine is cold. Putting hot air into the inlet is not everyone's
cup of tea since we spend so much time getting cold air intakes,
so it is up to you how you tackle this. You can either run a pipe off
it to a breather filter OR connect it back up as Henry intended.
I have removed it but its up to you. Here's a picture of where I mean.
Its been blocked in this pic

The Servo hose will not reach the servo, you will need to extend this to fit.
I used vacuum hosing and jubileeclips to ensure there would be no airleaks.

The fuel vapour hose needs to be blocked off, the 1.6 manifold doesnt use one.
It is located at the back of the inlet by the throttle body. See picture

Fit the new inlet and the induction piping, you need to re-use the
airtemp sensor off the old manifold - I cut a small hole in the
induction piping and tapped this sensor into it giving it a
tight air-leak free hold. There we have it, job done :-)

Guide written by Dazza @

Unfortunetly I have no pics of the finished thing as of yet (i.e a before and after shot)
My website:

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#128776 - 11th Feb 2006 1:40pm Re: 2.0 Focus Inlet manifold upgrade
Dazza Offline
Forum Master

Registered: 10th Nov 2003
Posts: 2899
Loc: Birkenhead
This upgrade would be ideal for anyone using a 2.0 zetec engine, but more importantly anyone thats fitted it into a Fiesta. The reason being the fiesta engine bay is cramped, especially between the engine and the bulkhead - You cannot fit the 2.0 Mondeo inlet as its too big so the majority of 2.0 Fiestas are using a 1.6 inlet, very restricted by port size.

Also this new inlet does not run over the camcover and across the exhaust manifold (It would absorb heat if using the old 1.6 inlet because thats what it does on that). If evtually your looking for 'big bhp' such as a Zetec turbo conversion you need to note the injectors, the original 1600 ones are side-fed which makes it extremely hard for replacements as most injectors are top-fed - Such as the Focus inlet which are much easily obtainable (Alot of japanese cars use them).

The upgrade is cheap for the amount of power/torque gained aswell as throttle responce. You can pick up a complete inlet for around 40-50 and considering its advantages its well worth it. This guide is easy to the average person and should have no probs completeing it - Allow for around 2-3hours work time too
My website:


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