Ford Fiesta ST Mk7 (ST180/ST200) Tuning Guide

Ford Fiesta ST Mk7 (ST180/ST200) Tuning Guide

Ford Fiesta ST Mk7 (ST180) Tuning Guide

 The Ford Fiesta ST Mk7 (ST180) is a popular hot hatch that offers exceptional performance out of the box. However, with some careful tuning and modifications, you can transform the Fiesta ST180 into a much more capable vehicle. Below is a detailed tuning guide covering key areas of aftermarket modifications, including intercoolers, intakes, brakes, turbochargers, and suspension.

Aftermarket Intercoolers


 Purpose:

The intercooler is essential in cooling the compressed air coming from the turbocharger before it enters the engine. Cooler air is denser, which improves combustion efficiency, resulting in better performance. The stock intercooler in the Fiesta ST180 can be limiting when aiming for more power, especially under prolonged aggressive driving conditions (heat soak).

Upgrading Options:

Aftermarket intercoolers are a critical upgrade for those aiming to run higher boost pressures or increase power beyond stock levels. They help in reducing intake air temperatures (IATs), thus preventing heat soak.

Popular Intercooler Brands:

AIRTEC Stage 2 Intercooler: Known for its excellent fitment and cooling performance. The core size is significantly larger than the stock unit, offering improved cooling capacity.

AIRTEC Stage 3 Intercooler: Quite possibly the most popular intercooler on the market, excellent fitment and headroom capabilities should you push the vehicle further with tuning in the future.

WAGNER Competition Intercooler: Huge 670mm x 270mm x 70mm stepped intercooler, 113% more intercooler volume than stock. Low weight option with 100% larger inflow area.

Benefits:

  • Reduced intake air temperatures.
  • Increased power potential, especially when paired with other mods (like turbo and intake upgrades).
  • More consistent performance over longer durations (important for track days).

Considerations:

Fitment: Ensure the intercooler fits properly behind the front bumper without requiring extensive modifications. All of the intercoolers listed upon the JXL Performance website are direct fit, some other brands/manufacturers may require modification.

Piping: Some intercoolers come with larger diameter piping to further reduce restrictions in airflow. Larger piping (or “boost pipes”) are recommended for higher power builds, especially for cars with an upgraded turbo.

Aftermarket Intakes

Purpose:

The intake system is responsible for providing the engine with air. The stock intake is designed with NVH (Noise, Vibration, and Harshness) and emissions in mind, so it's somewhat restrictive. An aftermarket intake allows for better airflow, resulting in improved throttle response, sound, and slight horsepower gains.

Upgrading Options:

There are several aftermarket cold air intakes (CAI) for the Fiesta ST180 that offer increased airflow over the stock system. Open cone intakes are also extremely popular due to the sound produced, but offer slightly less performance due to heat-soak.

Popular Intake Options:

GENUINE FORD ST200 Airbox– Offering an OEM+ fitment, the ST200 airbox features a lower air feed that forces cold/cool air through the intake. These kits work fantastically when paired with a performance drop-in filter such as the K&N Performance Filter for ST180 & ST200

ITG Maxogen Induction Kit – The ITG Maxogen Induction kit is very popular amongst Ford Fiesta ST owners, offering an aftermarket look/location, alongside the increase in sound and performance. This one is a winner.

AIRITEC Motorsport Stage 3 Induction Kit – Another extremely popular kit that features the crossover pipe and silicone connector that routes back towards the turbo, featuring a heatshield to prevent heat-soak, and available in a choice of colours, the AIRTEC Motorsport Stage 3 induction kit is suitable for completely standard, or highly modified vehicles.

Benefits:

  • Slight horsepower and torque gains (5-10 hp).
  • Improved throttle response.
  • Enhanced turbo and intake noise.
  • Better air filtration for performance applications.

Considerations:

Heat Shielding: Some intakes come with heat shields to prevent hot engine bay air from entering the intake system. This can help reduce IATs and maintain consistent performance.

Tune Required: While most intakes do not *require* a tune, some benefit greatly from a custom ECU tune to optimize the air/fuel ratio and make the most of the increased airflow. Most aftermarket intake kits for the Fiesta ST180/ST200 retain the standard MAF diameter, some products do increase this, which can cause MAF (Mass-Air Flow) problems. All of the kits available at JXL Performance are designed to be direct fit.

Brakes

Purpose:

Upgrading the braking system is crucial for controlling the added power, especially if you're driving aggressively or taking your Fiesta to the track. The stock brakes are decent for daily driving but can suffer from fade under heavy use, once you start to get them really hot you may experience brake fade (less braking performance) or a soft pedal (brake fluid getting too hot) – the products below will prevent that.

Upgrading Options:

Brake Pads & Discs:

Pads:

Ferodo DS2500: These pads offer much better bite and heat resistance compared to stock pads. They're ideal for fast road or light track use.

EBC Yellowstuff or Bluestuff: EBC offers a variety of brake pads, with Yellowstuff being a great all-around pad for road and light track, while Bluestuff is more track-focused.

EBC RP-X/EBC RP-1: The EBC “RP” range is designed to be used on track only, very track focused brake pads with great bite, however they take a little time to warm up and get to their effective temperature range.

Discs:

Genuine Ford – Genuine Ford discs are a great performing disc whether it is being used on the road, or for more spirited/track driving.

ProBite – Available in a variety of designs the ProBite brake discs offer a higher friction co-efficient than standard brake discs. All ProBite discs are offered with “ProCoat” a black-phosphate coating that protects against corrosion and grime.

EBC Brake Discs – EBC Brake discs are a popular upgrade to standard discs, offered in a number of designs and often paired with the EBC range of pads.

JXL Performance Brake Kit – Take the guesswork out of upgrading your brakes with our dedicated Ford Fiesta ST180 brake packages, consisting of brake discs (front and rear), pads of your choice, braided brake lines and Motul RBF600 brake fluid.

Brake Kits:

Big Brake Kits (BBK): For those looking for serious stopping power, consider a big brake kit. These kits typically include larger, multi-piston calipers, bigger rotors, and high-performance pads.

V-Maxx Big Brake Kit Upgrade (BBK) – V-Maxx Brake Kits for the Ford Fiesta ST180/ST200 are available in either 290mm (suitable for 15” wheels) or 330mm (suitable for 17” wheels). Available in a variety of colours and supplied with V-Maxx high performance brake pads they have become increasingly popular due to their TUV certification and high-quality components. (Fitment charts available)

EBC Racing Balanced Big Brake Kits (BBK) – The EBC Racing kits are available in 300mm, or 330mm and continue to grow in popularity. Supplied with everything you need in the box including race-spec brake fluid for the final system bleed.

Stainless Steel Brake Lines:

Upgrading to stainless steel brake lines improves pedal feel and responsiveness by reducing line expansion under heavy braking, JXL Performance recommends HEL, EBC or Goodridge braided lines.

Benefits of upgrading your brake components:

  • Shorter stopping distances.
  • Improved brake pedal feel and modulation.
  • Better heat dissipation and fade resistance.

Considerations:

Brake Fluid: Upgrading to high-temp brake fluid (like Motul RBF600 or Castrol SRF) is crucial if you're planning on doing track days to prevent brake fade.

BBK: Some big brake kits do not fit under the standard wheels without spacers or a different design of wheel, ensure you check any wheel fitment/clearance checks before purchasing to avoid disappointment.

Turbochargers

Purpose:

The stock turbo on the Fiesta ST180 is capable of impressive power, but it becomes a limiting factor when aiming for power over 240-245 horsepower. Upgrading the turbocharger allows for significantly more power potential, especially when paired with supporting modifications like a larger intercooler, intake kit and a dedicated tune. 

Upgrading Options:

Hybrid Turbos:

Hybrid turbos retain the factory housing but use upgraded internals (like a larger compressor wheel) for increased flow and power potential. These turbos offer a good balance of daily drivability and higher power.

Revo Stage 3 Hybrid Turbo: Capable of delivering around 280-300 horsepower when paired with supporting mods.

Laird Performance Outlaw 5Triple1: A popular, cost-effective upgrade which is increasing in popularity, designed to be direct fit, and rated to 355bhp, supplied with upgraded turbo elbow for maximum flow.

Larger Turbo Kits:

If you’re aiming for extreme power (350 hp+), you might consider a full larger turbo upgrade, such as:

Garrett GT2860R: Provides significant top-end power and is more suited to track builds – the nature and size of this turbo does mean you will experience more turbo lag, but this is a trade-off required for a higher maximum output.

Turbo Technics S280 – The S280 has been popular amongst Fiesta ST owners for many years now due to its flexibility, although this is considered a larger turbo, it can be run anywhere between 330bhp – 380bhp dependent on your goals, and current modifications.

Benefits:

  • Huge power increases (potentially over 330 hp).
  • More power throughout the RPM range.
  • Better top-end performance.

Considerations: 

Supporting Mods: When fitting a hybrid or big turbo, you MUST have supporting mods otherwise there is a high chance of the car underperforming, please check out our 340bhp guide below to see everything required.

Lag vs. Response: Larger turbos may introduce more turbo lag, so ensure your goals align with the characteristics of the turbo.

Fuel System: North of 350+bhp requires upgraded injectors for the ST180, the high-pressure fuel pump (HPFP) and low-pressure fuel pump (LPFP) do not require upgrading for this.

Engine Forging – Above 350bhp it is advised to forge your engine, although some people (including our own customers) run 350+ on a stock block/internals, you are very close to the threshold of requiring engine work – Check out our engine build parts here!

Suspension

Purpose:

The stock suspension setup in the Fiesta ST180 provides a decent balance between comfort and handling. However, for those looking for improved handling dynamics, a stiffer, more performance-oriented suspension setup is necessary. This is especially important if you're increasing power output, as improved traction and stability are critical for harnessing that extra power.

Upgrading Options:

Lowering Springs:

Lowering springs offer a simple and cost-effective way to lower the car’s centre of gravity and reduce body roll.

Eibach Pro-Kit: One of the most popular options, lowering the car by approximately 25mm while maintaining a comfortable ride.

ST Suspensions: Manufactured by KW, the ST Suspension Lowering Springs lower the vehicle by approximately 20mm, whilst retaining a compliant ride for road use.

H&R: The H&R springs are popular amongst those that want the visual look of a lower car, they lower the Fiesta ST180 by approx. 35mm.

Coilovers:

For those looking for adjustability (ride height, damping), coilovers are the best option. They allow you to fine-tune your suspension setup for road use, track use or even competition use.

Bilstein B14/B16: Known for excellent build quality and handling performance, Bilstein coilovers offer great value and ride quality.

KW V3: Offers adjustable damping and rebound, making them suitable for both road and track use.

BC Racing BR-RA: Coming in at a lower price point than the two coilover setups above, they may not offer as much adjustability, but they are extremely good for road use, and offer many benefits over the standard suspension.

Benefits:

  • Improved cornering and stability.
  • Adjustable ride height and damping with coilovers.
  • Reduced body roll for better high-speed handling

Considerations:

Ride Quality: Lowering springs or coilovers will make the ride stiffer, which can impact daily driving comfort

Alignment: After lowering the car, a proper alignment is essential to maintain handling performance and prevent uneven tire wear.

How to build a 330bhp Fiesta ST180/ST200

Building a 330bhp Fiesta is much easier than you may think – the Fiesta is a great platform for adding more power, however you must balance the modifications to ensure you are not lacking in handling or braking, to cope with the additional power, whether that be on the road or on the track.

All of the above modifcations should net around 330-340bhp on a healthy vehicle, we always recommend keeping up to your service schedule, especially when tuning and taking your vehicle to the next level, you can find the JXL Performance Ford Fiesta ST180/ST200 Servicing Guide here.

Conclusion:

The Ford Fiesta ST180 is a capable and fun platform with plenty of tuning potential. Whether you're looking to increase power, improve handling, or upgrade the braking system, there are a multitude of aftermarket options available. Remember, balancing your modifications is key to building a well-rounded car, especially if you’re planning on using it for multiple purposes (daily driving, track days, etc.). When done correctly, a tuned Fiesta ST180 can rival far more expensive performance cars in both speed and handling, making it a formidable competitor in the hot hatch world.

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