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
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,
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
Throttle body (TB) Brown Brown
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 @ TeamFord.co.uk
Unfortunetly I have no pics of the finished thing as of yet (i.e a before and after shot)