Unleashing Your Fiesta: Reconditioned & Tuned

Whether you're looking to breathe new life into a beloved Ford Fiesta with a reliable replacement engine, or you're an enthusiast eager to push the boundaries of performance with a highly tuned ST model, understanding your options is crucial. From ensuring your daily driver is back on the road swiftly and affordably, to transforming a hot hatch into a formidable track-day weapon, the world of Ford Fiesta engines offers a wealth of possibilities.

Finding Quality Reconditioned Ford Fiesta Engines

When your Ford Fiesta's engine gives up the ghost, or perhaps you're planning a restoration, opting for a reconditioned engine can be a smart and cost-effective solution. A reconditioned engine isn't just a used engine; it's a unit that has been meticulously stripped down, inspected, and rebuilt with new or re-machined components to bring it back to, or often exceed, original factory specifications. This process ensures reliability and extends the lifespan of the engine significantly.

Why Choose a Reconditioned Engine?

There are several compelling reasons to consider a reconditioned engine over a brand-new one or a simple used engine from a breaker's yard:

• Cost Savings: Reconditioned engines typically offer huge savings compared to buying a new unit directly from Ford, making them an excellent value proposition.
• Quality Assurance: Reputable reconditioners employ experienced workforces and modern reconditioning equipment to ensure the highest standards. Components like pistons, rings, bearings, and seals are often replaced, and cylinder heads may be skimmed or valves reseated.
• Warranty: Many suppliers offer a free warranty, providing peace of mind that your investment is protected.
• Availability: For popular models like the Ford Fiesta, reconditioned engines are widely available, often in stock for various models.
• Convenience: Services can include nationwide and international delivery, and some even offer a free valet service if you have the engine fitted by them.

Where to Purchase a Reconditioned Fiesta Engine

Providers like Ideal Engines & Gearboxes specialise in supplying reconditioned engines. They boast a large stock of reconditioned engines for all Ford Fiesta models, ensuring you're likely to find the exact engine you need, whether it's for a standard 1.0 EcoBoost, a 1.25 Duratec, or even a diesel variant. Their focus on top-class engine reconditioning, coupled with knowledgeable staff, aims to provide both best quality and discounted prices.

Tuning the Ford Fiesta ST Mk6: Unleashing the ST150

The Ford Fiesta ST Mk6, often referred to as the ST150 due to its 150bhp 2.0-litre Duratec engine, is a prime example of a 'fast Ford' – a big engine crammed into a little car, with a stiffened chassis designed for chuckable, useable fun. Much like its spiritual predecessor, the XR2, the ST150 boasts a fantastic chassis capable of handling significantly more power than its stock output. This makes it a highly tuneable engine, offering affordable yet formidable performance gains.

Over the years, the Mk6 ST has proven its versatility, from sensible fast-road conversions pushing around 200bhp to more recent, wilder builds featuring forced induction, approaching and even exceeding 500bhp. Its uncompromising and incredibly nimble chassis also makes it a strong contender on the track, embarrassing much more powerful machinery.

Initial Engine Upgrades for the ST150 (2.0L Duratec)

The 2.0-litre Duratec engine in the ST150 is renowned for its robustness. As long as you diligently monitor oil levels (as it does consume oil), you can dive straight into upgrades. A sensible first step, though not performance-enhancing directly, is a power steering relocation kit to prevent PAS fluid leaks at high revs – something you'll definitely be aiming for with tuning. An oil cooler upgrade is also often recommended for similar reasons.

Your tuning journey should begin with improving engine breathing. The original airbox is restrictive. Replacing it with a high-flow air filter kit, such as a K&N 57i, ITG foam induction kit, or the Mountune cold air induction system, will immediately free up some power and lay the groundwork for future modifications.

Once fresh air is flowing in, focus on getting the exhaust gases out efficiently. A cat-back exhaust system enhances the audible appeal, but for more meaningful power gains, consider a sports cat from brands like Scorpion, Piper, or Milltek. For off-road use, a decat option is available for maximum flow.

Combine these simple breathing upgrades with a suitable remap, and you can realistically expect to see around 165 to 170bhp, along with a much more enthusiastic driving experience.

Advancing Naturally-Aspirated ST150 Tuning

The next step in naturally-aspirated tuning involves upgrading the camshafts. A popular and proven choice is the Cosworth 200-spec camshaft kit, which can be fitted without needing to change valve springs and can help achieve up to 200bhp with supporting modifications. Other profiles from Newman Cams and Piper Cams are also available, often requiring double valve springs for very high lift.

To further unlock power in a high-spec naturally-aspirated build, attention turns to the inlet manifold and throttle body. Mountune and Cosworth offered unique inlets for their top-spec kits. While the original Mountune MR200 inlet is rare, replica Cosworth items are available from tuners like Jamsport and SiCo Developments, and Pumaspeed offers its own similar version. With these additions and a suitable remap, power can reach around 190-200bhp, which is considered the sweet spot for fast-road applications.

For those seeking even more power without forced induction, individual throttle bodies (ITBs) are the next logical step. Many ITB setups require a standalone ECU, but some kits are designed to work with the ST's drive-by-wire throttle and a remap on the stock ECU. While you can achieve over 200bhp, returns diminish, and each additional horsepower becomes increasingly expensive and time-consuming to extract. Extreme naturally-aspirated builds, often for race cars, can feature 2.3-litre bottom ends, ported and big-valve heads, aggressive cams, and enormous throttle bodies, potentially pushing over 300bhp.

Embracing Forced Induction: Superchargers and Turbochargers

While high-revving, naturally-aspirated builds can be thrilling, forced induction offers a more straightforward path to significant power increases for a road car. The ST's Duratec engine is remarkably receptive to boost.

Supercharger Conversions

Jamsport pioneered several bolt-on supercharger kits for the Mk6 ST using centrifugal Rotrex units. A stock Duratec engine can reliably handle up to 300bhp with standard internals under supercharged conditions. Due to the linear nature of boost delivery tied to engine speed, these conversions can even work effectively with the factory ECU. While a supercharger can be fitted to an otherwise stock ST, optimal results are achieved when combined with upgraded cams, exhaust systems, and improved inlets. Even higher power figures are possible with uprated internals and a larger supercharger unit. Supercharger conversions retain a naturally-aspirated feel behind the wheel, but with a substantial power boost.

Turbocharger Conversions

For the most dramatic leap in performance, a turbocharger conversion is unparalleled. This route typically involves custom-built setups rather than off-the-shelf kits, allowing tuners to tailor turbo choice, cam profiles, and engine specifications to individual requirements. The potential for big power is immense, with some Mk6 STs approaching 500bhp with well-spec'd turbo conversions.

Ford Fiesta ST Mk6 Transmission Tuning

The Mk6 Fiesta ST came equipped with Ford's common IB5 gearbox. While it lacks a sixth gear, its short gearing means it's rarely missed. The stock IB5 is robust enough for most applications, especially with naturally-aspirated tuning. However, a significant weakness is the lack of a limited-slip differential (LSD). The stock differential is also known to fail, often disintegrating and damaging the entire gearbox.

An uprated LSD is a highly recommended upgrade. For most road cars, a helical-type LSD like Quaife's ATB is ideal. Track and race cars might benefit more from an aggressive plated-type LSD from Gripper or 3J Driveline.

The standard clutch and flywheel are generally adequate for power increases up to around 200bhp, provided they are in good condition. Beyond this, an upgrade is necessary. Helix offers various options, from uprated organic clutches for road use to heavy-duty paddle clutch kits for track and race applications.

For highly boosted cars, a stronger gearbox like the MTX-75 is often essential. This is not a direct swap and requires modifications to the engine bay, along with a different clutch plate to suit the input shaft. An LSD becomes an absolute necessity with this conversion.

Ford Fiesta ST Mk6 Suspension Tuning

Developed by Ford's TeamRS division at the Nürburgring, the Mk6 Fiesta ST boasts fantastic handling straight out of the box. It's playful, communicative, and exactly what a hot hatch should be, though it does sit a little too high.

Few STs retain their original springs today. A set of lowering springs from Eibach not only improves the car's stance but also offers a slight performance benefit. The best option is to pair these springs with matched uprated dampers; Bilstein's B12 kit is a long-standing favourite and performs exceptionally well on the Mk6 ST.

For fast-road use, there's often no real need for coilovers, especially budget ones that can hinder performance and ride quality. However, for track enthusiasts, the adjustable settings and stiffer spring rates of quality coilovers can significantly help in perfecting the handling package. AST coilovers are highly regarded for the Mk6 ST, while ST's own coilover package offers a great balance between road and track use without breaking the bank.

Polyurethane bush upgrades from SuperPro or Powerflex are wise investments to replace worn rubber units and stiffen the chassis. Adding a performance rear anti-roll bar from Whiteline, along with rear axle spacers, creates a well-rounded suspension setup.

Dedicated track and race cars may opt for full roll cages and motorsport-spec rose-jointed suspension components for maximum stiffness, though these are often too much of a compromise for road cars. Air ride systems have also been used effectively on show cars.

Ford Fiesta ST Mk6 Brake Tuning

Don't be fooled by the seemingly small 258mm front brake discs; when combined with decent fast-road compound brake pads, uprated discs, and braided lines, they are perfectly adequate for spirited road use and have even proven effective on track in the Fiesta ST Championship.

A popular and cost-effective upgrade is fitting Focus ST170 300mm discs with Mk3 Mondeo calipers. This modification makes a noticeable difference on a very small budget and performs even better with uprated discs, pads, and lines.

Another in-house upgrade involves using the Brembo four-pot calipers from a Mk1 Focus RS. These require suitable brackets but will clear the stock 17-inch rims with the addition of wheel spacers.

Perhaps the best option for serious performance is a proper aftermarket big brake kit. Numerous options are available from reputable manufacturers such as AP Racing, K-Sport, and Hi-Spec, offering various disc diameters. This is crucial for track cars, where dropping an inch or two in wheel size can optimise handling.

At the rear, extensive modifications are rarely necessary. Simple disc and pad upgrades are effective. If bigger discs are desired, fitting the ST170's carriers to the Fiesta calipers allows for 270mm rear discs within the stock wheels.

Interior, Wheels & Tyres, and Styling for the Mk6 Fiesta ST

Interior Upgrades

The stock half-leather ST seats are comfortable and supportive for daily use, but for enthusiastic driving or track days, something offering better hold is desirable. Recaro Sportster CS seats (found in the Mk2 Focus RS) are an excellent choice, offering a perfect blend of comfort for long journeys and support for spirited driving. These, combined with rear seat deletion and a half-cage, can create an excellent club sport vibe.

Alternatively, reclining bucket seats from specialists like Corbeau offer a different aesthetic and allow for the use of performance four-point harnesses on track, while retaining the factory three-point seatbelt for road comfort. Dedicated track and race cars will opt for lightweight carbon/Kevlar FIA-approved race seats and matching harnesses.

Wheels & Tyres

The stock 17-inch multi-spoke alloys, while funky at the ST's launch, now look a little dated and are notably heavy. Replacing them with lighter aftermarket wheels offers significant unsprung weight savings, which can dramatically improve handling and acceleration. Many cast alloys offer savings, but forged alloys provide the biggest gains. For instance, replacing stock alloys (20.87kg each) with Team Dynamics Pro Race 1.2s (17.6kg) can reduce unsprung weight by 12kg, equivalent to removing 48kg of chassis weight!

This is also an ideal opportunity to experiment with offsets and increase width to fit wider tyres. Most road cars stick with 17-inch or drop to 16-inch wheels, but dedicated track and race cars often go smaller, to 15-inch diameter wheels, as this provides the best handling characteristics on the Mk6. For tyres, Toyo's R888R is a favourite for track use, but any quality tyre will do; avoid budget rubber to ensure you don't undo all your chassis improvements.

Styling Upgrades

The Mk6 Fiesta's chunky arches and funky styling possess a certain retro appeal today. While the car's design has a decidedly old-school feel compared to modern aesthetics, there's little need to drastically alter Ford's original styling. Many owners prefer a subtle approach, opting for a lowline kit and front splitter over more lairy kits or massive rear wings, though these options are readily available.

The Fiesta ST Engine: A Closer Look (1.6L EcoBoost)

Modern hot hatches of the Fiesta ST's size typically feature a 1.6-litre, four-cylinder turbocharged engine. The Fiesta ST's unit, commonly found in the ST180 and ST200 models, develops 180bhp and 214lb ft of torque in standard ST180 guise, sent to the front wheels via a slick six-speed manual gearbox. The ST200 limited edition model further boosts this to 215bhp on overboost (lasting 20 seconds in third and fourth gear) and 236lb ft of peak torque.

This engine is widely regarded as one of the best of its type. It pulls hard from low down in the rev range with virtually no discernible turbo lag, and unlike some turbocharged engines that feel flat at higher RPMs, the ST's unit revs out with genuine verve. While it may not replicate the raw, razor-edged excitement of older naturally-aspirated hot hatch engines, among contemporary downsized, turbocharged power units, it stands out as exceptionally good. The manual gearshift is precise and satisfying to operate, contributing to the car's accomplished dynamic makeup.

Forged Engine Rebuilds: Pumaspeed and Mountune

For those pushing the boundaries of power, especially with forced induction, upgrading internal engine components becomes crucial. This is where a forged engine rebuild comes into play, replacing weaker stock parts with stronger, more durable forged alternatives.

Pumaspeed Forged Engine Build Kit (1.6L EcoBoost ST180)

Pumaspeed offers a Wiseco Forged Pistons and ZRP Lightweight Rod set specifically for the 1.6 EcoBoost Fiesta ST / Focus EcoBoost engine. While the original equipment (OE) pistons and rods in the 1.6 EcoBoost are surprisingly robust, occasionally handling over 350bhp, they are not designed for sustained hard and heavy use at such levels. This forged set allows the 1.6 EcoBoost to reliably push well beyond 350bhp, with testing confirming capability over 425bhp. This kit provides everything needed to 'bulletproof' the motor, including options for ACL Race Rod Bearings or King Rod Bearings. Pumaspeed also offers fitting services at their head office, with an estimated labour time of 15 hours, making the total cost for parts and labour around £3,058.00 (inc. VAT).

Mountune Forged Engine Rebuild (1.5L Dragon Engine - Mk8 Fiesta ST/Puma ST)

Mountune provides a comprehensive Forged Engine Rebuild for the 1.5-litre Dragon engine found in the Mk8 Fiesta ST and Puma ST. This package includes Mountune specification forged pistons and steel connecting rods, designed to support substantially increased power, torque, and cylinder pressures. The assembly is performed by their highly-skilled racing division engine builders. Beyond the uprated rods and pistons, this upgrade replaces or upgrades numerous other key engine components for maximum reliability, including:

• Cylinder head gasket
• Big end bearing shells
• Head bolts
• Crank seals
• Timing chain, gear and guide
• Crank, ladder and flywheel bolts
• Water pump
• All other required gaskets / seals
• Engine oil and filter (Liquimoly)
• Coolant change
• Engine plaque

The process involves removing, stripping, inspecting, and multi-stage cleaning the engine, before rebuilding it with the upgraded components. The engine is then reinstalled, and all necessary fluids replaced. A 500-mile post run-in period engine diagnostic check is also included. This is a comprehensive drive-in, drive-out service at Mountune HQ in Hutton, Essex, typically requiring the car for approximately 5 working days. It's important to note that the engine will undergo visual and tear-down inspections, and any additional required work will be quoted before proceeding.

Frequently Asked Questions About Ford Fiesta Engines

Whether you're restoring a daily driver or crafting a high-performance machine, the Ford Fiesta offers a world of possibilities for engine enthusiasts. Understanding the options for reconditioned units and the extensive tuning potential ensures your Fiesta remains a joy on British roads.

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