mk3 guide!

Guest pisko

Posted April 3, 2005

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Posted April 3, 2005

Tydligvis noen som har fritids problemer på øyen der borte, men her er

MYE nyttig info angående historie, specs og oppgraderinger + nyttige linker.

Et must for nye mk3 eiere som gamle travere..

Fiesta

What is the Mk3?

Mk3 is the most popular Fiesta produced between 1989 to 1995, catering everyone from shopping trolleys to fire breathers. They are cheap to buy, cheap to maintain, reasonably reliable, and have very good tuning potentials.

What is the Mk3.5?

Mk3.5 is basically a slightly upgraded Mk3 to rectify some faults and to improve quality, produced between 1994 to 1995. Changes include flip open fuel cap, air bag(s), relocated electric window switches, relocated remote boot release switch, strengthen shell, and smoothed boot swage lines, plus some models also came with clear indicators.

What are the performance models?

- 1600cc 8v XR2i

108bhp, 1989-1992, CVH EFi, Mk3, insurance group 14

- 1800cc 16v XR2i

104bhp, 1992-1993, Zetec EFi, Mk3, insurance group 14

- 1600cc RS Turbo

131bhp, 1990-1992, CVH Turbo EFi, Mk3, insurance group 15, 0-60 7.7seconds

- 1800cc RS1800

128bhp, 1992-1994, Zetec EFi, Mk3-Mk3.5, insurance group 15, 0-60 8.3seconds, black interior trim

- 1600cc 1.6S

90bhp, 1989-1991, CVH Carb, Mk3, insurance group 9

- 1600cc 16v Si

88bhp, 1994-1995, Zetec EFi, Mk3.5, insurance group 8, black interior trim

What are the lesser models?

- L, LX, Bonus, Popular, Quartz, Finesse, Classic, Freedom are the most basic models

- Ghia is the luxury model with all electrical gadgets, only in 5-door form

- SX is the slightly sporty model with a roof spoiler and sports suspension

- Plus many more special editions!

What colours were available?

Solid:

Radiant red, diamond white, panther black (?), black

Metallic:

Mercury grey, cayman blue, java blue, moondust silver, ash black, mallard green, dark aubergine purple, burgundy red, matisse blue, tasmin blue, petrol blue, tourmaline green

What engines were available?

- HCS

8v, as fitted to low power 1.0, 1.1 and 1.3 models

- CVH

8v, as fitted to 1.4, 1.6 and some performance models

- PTE

8v, upgraded CVH, as fitted to the 1.4 Si and Ghia only

- Zetec

16v, revvy modern engine (1.8 and 2.0 versions have very strong bottom-end), as fitted to performance models

For history of Zetec see here http://fiestaturbo.com/content.php?page=zetechistory

Only 1600cc and 1800cc are available for Fiesta

What brakes were available?

- Solid

240mm, as fitted to older and lesser models, single pot

- Vented

240mm, as fitted to performance and ABS models, single pot

Notice that the calipers are not compatible due to different disc thickness.

What were the optional extras?

- Central locking

- Electric windows

- Centre console

- Remote boot release

- CD/Cassette player

- 4-channel sound system

- Rear wiper/washer

- Front intermittent wiper (default is single-speed)

- Heat windscreen

- Fog lamps

- RS Accessories bodykit (see Styling section)

- Colour coded bumpers/mirrors

- Spoiler

- RS Accessories lower spoiler

- Power steering

- ABS

- Split rear bench

- Alloy wheels

Apparently, some models have some of the above items as standard. And some extras were not available to certain models.

Common Problems

Where is rust likely to be?

Rear arches, and under sill. This is a VERY common problem for Fiesta.

Area around the petrol cap is also a major problem for Mk3, which is why the

Mk3.5 has got flip open petrol cap.

Also check under passenger side footwell carpet. Sometimes water got trapped in and causes havoc.

My clutch pedal sometimes goes all the way down and won't come back until I pull it up!

Clutch ratchet (quadrant) is on the way out. It is not particular a very hard job to replace, but it is very very fiddly. So set aside a few hours...

My car doesn't idle properly, or is running rough

Most likely you need to clean to Idle Speed Control Valve (ISCV), which is under the inlet manifold. Over time it gets very dirty and needs to be soaked in carb cleaner. If the car runs fine after cleaning, but the symptom returns after a few days, it is likely that the ISCV is knackered.

Or it might be the MAF sensor. Read here

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=81677 for more details.

Heater fan, radiator fan, and boot switch don't always work?

Read this post http://www.fiestaturbo.com/phpBB/viewtopic.php?t=83284 and check it over RIGHT NOW!

This is a very serious problem and the relay should be replaced as soon as possible if there is any problem found.

The indicators won't cancel themselves!

The indicator switches on the steering column multi-functional switch are faulty.

A replacement steering column stalk assembly can be bought at scarp yards for around 5 to 10 pounds.

Tuning, Handling & Braking

Where can I get an induction kit for my 1.1 carb?

There is no induction "kit" available for 1.1 carb. Try the carb bolt-on filter from K&N.

Guide to obtaining and fitting the filter can be found here

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=62698

It will not give you any power increase, but will make the car louder... and possibly poorer running in cold.

My HCS engine Fiesta is very noisy!

You need to adjust the tappets, where the procedures can be found in the Haynes manual. (check Valve Clearance Adjustment)

If it is still noisy, try this method here

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=62484

What is a ZVH engine?

It is a CVH engine (probably with a turbo) with Zetec 2.0L bottom end, so that the car can keep the modified head while having a bigger capacity and stronger bottom end.

Have a look here http://www.jimhearne.co.uk/zvh.htm for some comprehensive info on ZVH.

What is the most cost effective way of getting more power for my Si 1.6?

There is little point tuning the 1.6 Zetec, as the head is very restrictive.

The most cost effective way would be putting a Zetec 2.0L engine in. It is straight in without too many things to change.

Notice that you CAN use the 1.6 ECU, but it will under-fuel at high rev range.

Some more info here http://www.fiestaturbo.com/phpBB/viewtopic.php?t=58354

Refer to the next question for more info.

Can I put a Zetec 2.0L engine into my Fiesta?

Most probably you can. Notice that the Zetec 2.0L engine can be found in Mondeo, which is apparently quite popular and quite easy to find. A complete 2.0 engine can be bought privately for as little as 100 pounds, or around 400 pounds from trade for an average mileage one with warranty.

The 2.0 engine produces around 130bhp which is quite nice for a small and light car like a Fiesta.

See here http://fiftyonecl.hopto.org/st2000/ff3engineswaps.html for what exactly need to be swapped.

See here http://www.fiestaturbo.com/zetecconversions for some prices.

Contrary to common belief, the insurance is not as scary as thought to be.

Certain insurance companies, like HIC, consider a 2.0L powered Fiesta Si to be of group 9 insurance (i.e. same as a 2.0 Mondeo). But of course, the final quote depends on many things.

Can I put a Cosworth engine into my Fiesta?

Nothing is impossible providing enough time and money are given. But the costs would probably exceed the expectation of common people. Rumours are that it would cost over 10k pounds, which is quite believable.

Just bear in mind that a Fiesta and a Cosworth are two completely different cars.

How do I get 130ps from my 1800cc 16v XR2i?

You need to get the throttle body, MAF sensor, camshafts, and ECU from a RS1800 or a Mondeo Mk1 2.0.

Notice that although the diameters of RS1800 throttle body and Mondeo 2.0 throttle body are pretty much the same, it is easier to fit the RS1800 item due to the mountings.

What are the more "advanced" tuning routes for my Zetec engine?

- Turbocharging

A very complex topic in itself, but all the most powerful Fiesta in this country are running Zetec Turbo. Basically there are two ways of doing it, the proper way and the budget way.

Proper way: Forged pistons and aftermarket management system (such as Pectal), and have it built by Ian Howell! There is no set cost for this - the sky is your limit.

Budget way: Spacer plate and FRST management system, with ERST turbo unit and exhaust manifold, notice that the 1.8L engine has stronger pistons and smaller bores than the 2.0L engine, hence is more suitable for this application. But it is VERY unsafe to run over 1bar (14.7psi) on this setup. 8psi recommended. This budget turbocharging can be done for as little as 1000 pounds.

See here http://www.fiestaturbo.com/phpBB/viewtopic.php?t=77570 for some links to various topics.

- Supercharging

I got a quote from Autocraft SVE http://www.autocraftsve.co.uk for 3,650.00GBP for a supercharger (ProCharger from the US) supplied and fitted to a 1.8L Zetec with dyno run before and after, with expected power gain of 50%.

I personally have no experience (nor have I heard of anyone has) with this company, so I can't comment on it any further.

- Throttle Bodies

Throttle bodies kit can be bought from 1700 to 2500, where the most popular choice seems to be Webber Alpha kit (including inlet manifold, throttle bodies, fuel rail, injectors, management, linkage, etc).

Compared to turbocharging or supercharging, the installation is relatively easier. Labour for fitting and mapping should be around 400 to 700.

It would give 30bhp power increase on average. Fuel consumption is not very good, but is better than twin carb anyway.

What brake setups can I fit to my Fiesta?

- Cosworth 4x4 or Granada V6 Cosworth (Mk3)

These are single-pot, 278mm setup.

They go straight on with some spacers/washers, and drilling (enlarging) the mounting hole from 10mm to 12mm.

Notice that Cosworth 2wd brakes WOULD NOT fit due to different offset.

By "Cosworth 4x4", I mean Escort Cosworth 4x4 and Sierra Cosworth 4x4.

Minimum wheel size is 15", but still they might not fit depending on the design of the wheels, so 16" recommended.

Here is a guide http://www.fiestaturbo.com/phpBB/viewtopic.php?t=29615

- Mondeo V6 (Mk1 and Mk2) or Scorpio V6 Cosworth

These are single-pot, 278mm setup. The Cosworth 4x4 and Mondeo V6 calipers, discs and pads are very very similar.

They go (pretty much) straight-on when the carriers are machined 3mm or 4mm off the surface, or if you are brave you can space the discs out by 3 or 4mm. Drilling (enlarging) the mounting hole from 10mm to 12mm is also required.

Apparently Mondeo V6 brakes are cheaper and easier to find than Cosworth ones.

However, Ford "economically" fitted some 260mm setups to some of the V6's. So make 100% sure when you buy second hand.

Minimum wheel size is 15", but still they might not fit depending on the design of the wheels, so 16" recommended.

- Focus ST170

These are single-pot, 300mm setup. Apparently these are monsters and very very good at stopping.

They go straight on with drilling (enlarging) the mounting hole from 10mm to 12mm.

They usually can be found on various Ford forums for around 300 pounds.

Minimum wheel size is 16".

- Escort RS2000 (Mk5, Mk5b, Mk6)

These are single-pot, 260mm setup.

They go straight on without any modifications.

Minimum wheel size is 14".

- Fiesta ST150

These are single-pot, 278mm setup.

They go straight on with drilling (enlarging) the mounting hole from 10mm to 12mm.

Minimum wheel size is 15", but still they might not fit depending on the design of the wheels, so 16" recommended.

These are quite rare at the moment because the ST150 isn't even for sale yet!

And of course, many aftermarket setups from Godspeed, Hi-spec, Wilwood, Brembo, Tar-ox, etc...

How do I bleed the brakes?

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=77380

Do I need a FSE Power Boost Valve?

The Fiesta RS Turbo and 8v XR2i already have adjustable fuel pressure regulators.

So the "Power" Boost Valves are pointless - moreover they must be set up on a rolling road to work properly.

How do I upgrade my turbo from T2 to T3?

http://www.fiestaturbo.com/content.php?pag...ormat=showphoto

Styling

Can I fit XR2i or RS Turbo bumpers to my lesser model?

Yes, they go straight on. Refer to the Haynes manual for how to remove and put on bumpers.

Can I fit XR2i or RS Turbo arches/skirts to my lesser model?

Yes, although bonding might be easier than drill holes.

See the guide here http://www.fiestaturbo.com/phpBB/viewtopic.php?t=47924

Can I fit XR2i or RS Turbo arches/skirts to my 5 door model?

Yes, but it is very difficult to get a perfect fit.

See these two thread for some ideas.

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=53631

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=52687

Can I fit opening (pop out) rear quarter windows?

Yes, but not as easy or as cheap as I thought it would be.

See the guide here http://www.fiestaturbo.com/phpBB/viewtopic.php?t=29482

Can I fit Mk4/Mk5 interior to my Mk3?

Yes, read here for some comprehensive information http://st2000.s5.com/ff3latespecinteriorguide.html

Notice that it is very difficult (or nearly impossible) to fit Mk4/Mk5 front seats into a Mk3, but to Mk3.5 is no problem.

Dash wiring is quite a nightmare too.

What bodykits are available?

- XR2i / RS Turbo Style

- Si Style

- Si Xtra Front Bumper (Si bumper with 2 extra lights, and a splitter)

- RS Accessories Kit (under bumper spoilers and skirts)

- RS Accessories Kit *new version* (Very rare, looks like a crossover between Cosworth and Si style)

- Cosworth bumpers (based on Escort Cosworth)

- WRC front bumper (based on Escort Cosworth WRC)

- Mondeo Estate spoiler (to be fitted over normal spoiler)

- Combat Kit

- Delta Kit

- Samurai Kit

- 12bore Kit

- Flycatcher Kit

- PSG Wide-arch Kit

- Skyline Kit

- RS2000 Skirts (based on Escort RS2000)

- M3 Skirts

Some people like to fit Mk4/Mk5 rear bumper too, especially the Zetec-S one.

It goes well with a flush tailgate.

Check out the links section (bottom of this FAQ) for where to buy them.

Can I fit 90-spec ERST Recaro seats to my car?

Yes, but not straight forward. You'd need to make up some brackets.

See here for more details

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=52376

Is there any way I can get a single wiper conversion within a tight budget?

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=60457

What size of wheels can I fit without much headache?

15" wheels with 195/45/R15 are good for most people, unless the car is radically lowered.

If they rub, it is usually rubbing against the suspension components not arches. Spacers of a few mm would likely sort it out - don't forget to fit longer studs if required.

How do I fit 17" wheels?

You'd need arch modding to fit them.

http://www.fiestaturbo.com/content.php?page=fitting17s

Can I fit Escort Cosworth wheels?

They are very wide and are generally a nightmare to fit. But it is (sort of) possible - cut arches, remove inner wheel black rubber protection trim, use mad spacers, restrict full-lock, and hope they do not extrude too much to be illegal.

How do I fit neon?

Neon is so yester-year. You want cold cathode tubes! Smaller, brighter, cheaper, less power consumption, and less heat. Read here for a guide on how to fit them to the boot. http://www.fiestaturbo.com/phpBB/viewtopic.php?t=72826 Fitting them to footwells follows the same principle.

Electrical/Electronical

How do I fit central locking?

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=79801

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=47636

The procedures are the same for 3-door and 5-door.

How do I fit electric windows?

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=79801

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=51066

The procedures are the same for 3-door and 5-door.

How do I fit a remote boot release?

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=79801

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=47682

How do I fit an intermittent wiper stalk?

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=82150

How do I fit a lights on warning buzzer?

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=82082

How do I fit a rev counter (tachometer)?

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=51448

How do I change the clock to blue-lit?

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=80771

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=44471

How do I change an XR2i loom to FRST OFAC or OFAB loom?

http://www.fiestaturbo.com/phpBB/viewtopic.php?t=77331

Does the management system of my Fiesta has OBD-II interface?

No, the Mk3 uses EEC-IV management system.

Only EEC-V has OBD-II.

Is the PATS on my car internal or external?

All Ford cars up to 96 have external PATS.

ICE

What size are the original front door speakers?

They are 13cm (5.25"). The "multi-fit" design speakers should fit without any work to the mounting, although new connectors on the original speakers cables are apparently required.

What are these wires behind my headunit?

Red = permanent live (to headunit Yellow)

Yellow = ignition/accessory live (to headunit Red)

Brown = earth (to headunit Black)

Yellow/Grey = lights-on live (no connection to headunit)

By "headunit", I mean an aftermarket headunit using the ISO wire-colour standard.

Buying/Selling

No idea! Please help!

Links

Fiesta sites

http://www.ukfiestanetwork.com (another popular Fiesta community, more for Mk4/5/6 than Mk3)

http://www.fiestaprojects.com (everything you ever wanted to know about Fiesta Mk3! Site under re-construction)