[EN] Focus Mk2 (EU, 2005) quick help

2016-02-10_04-30-26 by stavros mlls, on Flickr

Focus ST225 new exhaust manifold gasket. Here are the finis codes.

IMG_20160216_104418 by stavros mlls, on Flickr

and O ring

IMG_20160216_110002 by stavros mlls, on Flickr

Waiting for the exhaust manifold stud and Nut kit with Allen Key Inserts..

2016-02-17_09-43-29 by stavros mlls, on Flickr

A new water pump arrived today. A good after market product on the 1/3 of the price of oem pump..

IMG_20160217_121247 by stavros mlls, on Flickr

Motul Gear 300 as one of the best gearoils for the M66

2016-02-18_03-13-26 by stavros mlls, on Flickr

ST 225 Anembo exhaust manifold reinforced studs and nuts ..

2016-02-25_02-14-30 by stavros mlls, on Flickr

Focus RS mk2 Luk clutch kit

IMG_20160226_143019 by stavros mlls, on Flickr

IMG_20160226_143134 by stavros mlls, on Flickr

IMG_20160226_143200 by stavros mlls, on Flickr

IMG_20160226_143235 by stavros mlls, on Flickr

Watched the whole thread, very nice work you doing there. Started from a little "scratch" and now it's a different car.
Keep up !

FORScan app and ELM 327 Wi-Fi

2016-02-29_02-26-54 by stavros mlls, on Flickr

Silicone hose reducer from 3" to 2,5" (Black)

received_1679043522334487 by stavros mlls, on Flickr

received_1679043499001156 by stavros mlls, on Flickr

received_1679043515667821 by stavros mlls, on Flickr

Farewell my loyal friend!

IMG_20160317_152654 by stavros mlls, on Flickr

emptiness..

IMG_20160317_152506 by stavros mlls, on Flickr

So after engine removal it is time to deal with the wiring loom.

A great Thank You! To my friends Thomas and Nikos who helped my to find a way to deal with all these wiring mess

IMG_20160318_163318 by stavros mlls, on Flickr

IMG_20160318_230452 by stavros mlls, on Flickr

Wiring chaos as i didn't want to keep the ST225 factory ESP, so i changed it to a simple ABS

IMG_20160318_230441 by stavros mlls, on Flickr

IMG_20160319_140010 by stavros mlls, on Flickr

These are the differences between the two gear towers. The black one is the 2.0 Duratec HE with MTX-75 5speed gearbox. The white is the ST225 gear tower 2.5 HYDA engine with M66 6speed gearbox.

IMG_20160319_124003 by stavros mlls, on Flickr

IMG_20160319_124128 by stavros mlls, on Flickr

and the gear cables are different also.. and i found very difficult to change them..

IMG_20160319_130248 by stavros mlls, on Flickr

Although i knew that i got the extra two holes to fit the rear bolts of the new gear tower, when i tried to fit it on position i realized that on my 2.0 3/2005 model there were no screw threads on the holes..

IMG_20160319_124207 by stavros mlls, on Flickr

IMG_20160319_124235 by stavros mlls, on Flickr

Caution!

Although the clutch pedals looks identical they aren't!
The ST225 has an extra spring and a cable that connecting the pedal with the engine wiring.
So in order to make a proper retrofit you must change the clutch pedal also..

20160321_155234 by stavros mlls, on Flickr

20160321_155245 by stavros mlls, on Flickr

Time for cleaning. A tidy and fresh engine bay was always priority for me.

20160321_190821 by stavros mlls, on Flickr

A Great moment today! up! up! up!

final 22-3-2016 by stavros mlls, on Flickr

ST225 or XR5 maf sensor with housing

IMG_20160324_170105 by stavros mlls, on Flickr

IMG_20160324_170053 by stavros mlls, on Flickr

IMG_20160324_170119 by stavros mlls, on Flickr

Finally the engine met the body! And what a combination!!!

IMG_20160324_155604 by stavros mlls, on Flickr

After hours and hours of reading and comparing and checking we got all connectors plugged in and its time for the first electrical system testing..

IMG_20160324_163356 by stavros mlls, on Flickr

Final moves and we turn the key on to give life on electrical system!

IMG_20160324_175924 by stavros mlls, on Flickr

.. And.. what a rilif. Everything work! it's fantastic!
Thomas face on steering got this well known victory expression!

IMG_20160324_174353 by stavros mlls, on Flickr

..and here is the Major Proof that my suspicions were Right!

This is the 74,5mm Porsche 911 GT2 RS throttle body plugged in the stock Ford connector!!!

It works like stock!!! Positions: steady -opened - closed, No Faults No Errors on dashboard!!!

Now I just need an adaptor plate slightly modified to match the stock ST225 manifold !!! Hurray!!

IMG_20160324_180536 by stavros mlls, on Flickr

The two rear bolts for the gear tower are ready and also the extra connector that prohibits the selection of reverse gear after 25 km/h in order to avoid a misplaced selection (instead of sixth gear) while moving.

We are getting closer and closer.. can't wait to fire up the starter..

IMG_20160324_150454 by stavros mlls, on Flickr

Another unexpected malfunction of the clutch pedal pump this time, led me to buy a new one..
I'm getting tired and i'm starting losing my patience ..

IMG_20160330_144854 by stavros mlls, on Flickr

IMG_20160330_144843 by stavros mlls, on Flickr

So the story goes on and on .. The ST225 (XR5) has an extra mount for the exhaust that 2.0 Duratec didn't ..

IMG_20160401_161708 by stavros mlls, on Flickr

Final steps.. Almost ready..

IMG_20160401_151155 by stavros mlls, on Flickr