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badboy fiesta si 2.0 16v cosworth interior

basically what you need to looks at is the parts you've used of the 1.6, and how they are restrictive.

EGR, is the commonly known name for the pulse air system that's fitted to the standard 1.6 exhaust manifold.
it consists of piping that protrudes into the exhaust gas air, restricting the flow, in theory.
it is not a necessity, it's there to help cat warm up

Inlet manifold, you want the best you can get. i have a fiesta RS1800 one on mine, it has a substantial difference in the port diameters. Trust electrical do make and inlet manifold for the zetec but it needs modifying to suit your application.

induction, i run a k&n 57i kit on mine. the one that came with my car.
although i'm considering purchasing an air box and trying the panel filter and seeing if i notice any difference

Exhaust, get a good quality stainless steel exhaust system, not only will it out live your car it will look/sound better than standard and give a healthy performance increase
HTH
JJ

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My ebay stuff


Is that the best you can do?
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2000 V70 T5 SE - 2.3, 5 cylinder, 20V, VVT, Turbo, 250bhp, cream leather, climate control, the works!