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2008 Focus Zetec 1.6Tdci Build Thread

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just joined the forum and thought i would share my progress with one of my fords, i shall put the mondeo on another thread, so here is the focus

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  • Author

this is it the day after i bought it, 2008 focus zetec

full service history

previous owner had bought the car from ford direct and it is reasonably clean and rust free

only one problem with the previous owner, he was a freelance photographer and done 40,000 miles a year, on one service, needless to say that's not too good for the engine.

I bought the car at a very cheap price as it needed an engine and turbo, no3 big end was totally nackered and the resulting metal i n the oilhad destroyed the turbo

  • Author

here is the no.3 big end journal, in a pretty sorry state, bearing which is almost worn through and the big end of the conrod which is also damaged and now slightly oval

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  • Author

managed to get an engine and turbo from a reputable breakers, guaranteed for 6 months with 63000 miles on them, fitted round my mums back door, much to her delight of course, and 2 weeks after buying the car she is ready to go back on the road.

now its time to got to work, first job is the wheels, bought a set of focus st wheels off ebay with tyres, wheels needed refurbished so i one weekend we set to them, i wanted them a matte anthracite colour, i have my mondeo wheels this colour and cant get enough of it. first two pictures show the wheels painted up and ready to fit, the paint is from an aerosol can, cant remember the name of it but its actually a reanult colour, bought the tins from my local reanult dealer as they use it to paint trims on some models.

3rd and 4th pictures are the wheels fitted to the car, i think it looks too high now so i put 40mm pro sport lowering springs on the car, the result is the final picture, also have the windows tinted by this point

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  • Author

dont have any pictures of my next tasks but they are as follows

auto dimming rear view mirror

bought off ebay from a 2006 st, only requires 3 wires to fit so very easy, 1 earth which can be found at the ariel, 1 12v positive feed which i took from the gem module, out of a battery saving circuit so it wouldnt drain the battery, and while i was down there i found my reverse signal feed to un-tint the mirror when in reverse.

higher spec interior light

got this from a mk4 mondeo, has 3 bulbs instead of 1, a main festoon inside with 2 capless maplights, all have been changed to led. plugs straight in but as this had led's for ambient lighting i had to take a feed for the sidelights to turn the ambient lighting on. If anyone is wanting to do this, regardless of trim level, the feed is in a grey plug behind the passenger side a pillar trim.

handsfree bluetoth

i had a spare bluetooth module lying around so all i needed was the wiring, unfortunatley my focus didn't have the wiring in place for this so i had to make a loom. I went to a breakers yard in search of the loom i needed, found a focus with it but the wires go into the main dash loom, so i cut the plug from the bluetooth module behind the glovebox, and the 2 plugh behind the cd player, one black and one white. I managed to create my harness using the wiring diagram from etis and installed it in the car, was easy once i found my ignition feeds. I will try and find my info regarding it incase anyone wants to do the same. once in the car i just had to get a microphone for it, you can either buy the ford microphone or fit your own, i had an old parrot kit lying around so i used the mic from that, managed to fit it inside the holes in the interior light for the ultrasound.

carbon fibre wrap on the centre console and cd player surround

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Looking good so far mate. :)

liking what you have done so far

  • Author

cheers for the replys guys, the next few photos are of the inside of the car, about 3 weeks ago i decided i wanted the headcloth and all the upper trims matte black like the st models, so i got to work stripping the pillar trims and headcloth out the car.Cleaned all the plastic parts with hot soapy water and painted them, firstly with plastic primer, then matte black. looks great now its in the car, feels nice and dark like an st. The headcloth looks fine in the car, although in the pictures with the flash on it looks like a zebra

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  • Author

Here it is as it stands now, full zetec s kit fitted, might paint the front grilles gloss black in the future, tho i cant decide what to do.

I have also blanked off the egr valve and removed the internals of the DPF, dont have any pictures of it but was fairly easy to do. My car is euro 4 + DPF, it has not been remapped to compensate for it not being there but so far iv had no warning lights so i think this would only be possible on a euro 4 car, euro 5 would need a remap.

Next up this week is my new instrument cluster, it currently has the standard cluster with the square lcd display, which has all the usual extras enabled, like DDS, Eco moe and radio/phone info in the display. I have purchased a speedo with the large tall lcd display, will hopefully get it fitted and coded this week at work

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Looks good........needs a was though lol :D

  • Author

It does need a wash. Just noticed how dirty it is in they pictures. i intend on getting it washed and machine polished at some point, probably next weekend then il get some shiny pictures of it.lol

Looks excellent mate,

I see its been lowerd aswell,

There is a member Charlie Brigante in birmingham was selling a black roof lining from an ST he may still have it,

When logged on via pc or internet browser click on my profile page for a list of guides may give some ideas ST pod fitting guide, front&rear footwell lighting dual reverse lighting, dual cam dvr system etc.

http://www.fordownersclub.com/forums/user/14733-lenny/

Look forward to watching progress looks great.

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