Phaeton S3 Autotester - 2019 update / ST170 lump!

[Roy Kemp]

Hello all, and belated HNY to everyone!

I didn't manage to get the Phaeton out as much as I'd have liked last year, and I'm still waiting for that first win. Even in little events where it's me versus three Micras... quite embarrassing.

Anyway, I got the rear leaf spring mounts beefed up nicely after on failed. One rear damper was shot so it's on new spax gas adjustables at the back, and polybushes on the whole rear end. Other than that, we didn't really upgrade much last year.

So, let's do some mad shit in 2019. I've verbally bought a Focus ST170 as an engine donor, picking it up when I get home. Now, compare a historic photo of the Phaeton engine bay:

With pinched-from-the-internet photos of an ST170 lump...

So, from what I can gather from some brief research, my main headaches will be:

• Steering column. That massive inlet manifold with dual-length intakes is gonna sit right where my column is. As I want to keep everything OEM for now, I'll have have to find a way to re-route the column with UJs. It's already on a hybrid column due to running Corsa PAS so more chopping about will be required.
• Bulkhead. Look at the throttle body and EDIS module, and how far back they sit from the rear of the engine. They're going to interfere with some fibreglass. I reckon the EDIS will relocate somewhere, maybe with longer leads, but the TB is just where it is. Some bits of tub may have to be sacrificed. Thermostat housing might also be a pest.
• Clutch / flywheel. The ST170 is a dual-mass fly and the box has an atypical number of splines. So it'll all have to go. I believe an 1800 Zetec flywheel is the one to use, anyone got any more info than that? I'm guessing the CVH stuff will be no use, as the crank firing signal is taken from a trigger wheel on the front of the crank.
• Exhaust. This will again be a suck-it-and-see job. The ST170 has a nice manifold as standard, 4-branch strainless with long primaries in a 4-2-1. Unfortunately it's designed for FWD. Would be nice if we can re-use as much of it as possible, but it's not going to come anywhere near my existing pipework.
• Auxiliary belt. Losing the PAS and AC leaves a choice between adding an idler to keep the stock water pump spinning the right way, or run an even shorter belt with a grooved water pump pulley and reversed impeller. I reckon cheapness will be the order of the day.
• Sump. I think the CVH one can be adapted. Some say it's a straight fit. We'll see.

And things that shouldn't be too much of an arse...

• Engine mounts. I believe all Zetecs are much the same, and the CVH is in the same boat. My car previously had a Zetec before I bought it, hoping the mounts are going to bolt right up to the ST170 lump. Note - although it's badged "Duratec", it's actually a late-model Zetec - basically a Blacktop with a trick head and internals.
• Cooling. I'll be keeping an eye on temps but the Civic 3-row alloy rad, although a cheapie, may well be enough. Pipework will be home-made from existing stuff.
• Electrics. All OEM Focus still will be retained, so just a case of grafting it into the Phaeton loom. How hard can it be?

Anyway, I can't find any evidence of anyone else with the ST170 engine in a Dutton, unless anyone else knows better?

Any advice or guidance would be much appreciated!

[Adrian Southgate]

Always best to have the donor for the duration of the build... just in case.

[Roy Kemp]

Yeah, I remember you saying that Adrian, that's a lot of value going to scrap! I bet they can't be arsed with the "all electrics" part of your request. That would be a pain for them. I think the best you could ask for is an hour or two alone with each ST to gently remove the electrics before they go pulling the rest apart!

I'm paying 450 for a 98k car that's running, complete, but rotten and has been sitting for 6 months. Which is possibly high as the engines change hands for £200. But hearing it running first is always worth paying a little extra for.

Plus, by the time I punt the interior, wheels, brakes, gearbox, bumpers etc I should be closer to the £200 mark, so not all bad. 

[Adrian Southgate]

I suppose nows not the best time to tell you that our local breakers yard are crushing the ST170's with the engines still fitted, I have put a word in to see if I can get a couple on a pallet complete with all electrics but nothing back yet.

[Roy Kemp]

Thanks for the encouragement James :)

[Roy Kemp]

Forgot to add:

Fuel Tank. Doubt we'll be able to shoe-horn the Focus tank into the Dutton boot, and the old Escort van one isn't fit for injection. Maybe an Elise tank will pop up cheaply? Or a cheaper alternative fit for high-pressure fuel injection? Anyone?

[James Doulton]

Crumbs, there's lots of bits where you haven't really got room for extra stuff - on the drivers side and at the rear of the engine. There are others who have fitted Zetecs but I don't remember any that have kept the standard inlet manifold.