I am trying to build up a guide of parts needed to fit a zetec (all models) into locost/avon etc any contributions welcome. Looking for flywheel,clutch,starters or any other information wiring etc. It seems the zetec is the engine of choice for the future ?

Dave
FWIW, my options were:
stock 2 litre Zetec motor
Sierra CVH flywheel and clutch kit,
Sierra CVH front 'chopper' mounted on Zetec front pulley,
Sierra CVH starter,
Daihatsu Charade alternator,
Tiger alternator bracket (don't bother - rubbish),
Fisher Fury exhaust manifold,
Twin 45 DCOE's and Burton manifold,
Dunnell sump,
Raceline water rail (normal thermostat housing not possible),
Emerald Management system (but cheaper options available),
1800 cc Water pump,
Hand made wiring loom.

I can email photos if you wish.
Regards

Wyn

Wyn, Any chance of putting them in an archive so we can all see. Although I`m building mine with a xflow in the 1st case, I`m coming round to the idea of replacing that with a Zetec eventually, I reckon I can probably do that for less than it will cost me to build a hell burning xflow, the 1st engine will be a simple get me on the road one, with an upgrade down the track. Thanks, Steve.

quote:

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Originally posted by dave1888
It seems the zetec is the engine of choice for the future ?

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yeah ok the duratec engine IS the choice but i think a lot of people will go for the zetec in the first instance as duratec parts standard and aftermarket will still be too costly

How much can I expect to get for a 2.0 litre Zetec of unknown provenance? I got it with the kit but it is surplus to requirements as I am going ot use a 16v Citroen XU engine instead. It has the standard inlet manifold c.w. injectors, stock exhaust manifold, alternator, starter & some other sundry bits 'n bobs. Don't know anything about it's history/mileage/condition. Answers please?

My install not too far from lsdweb's

stock 2 litre Zetec motor from 50K rear ended automatic (make sure you change the crank position sensor housing for a manual one).
Escort 1.8 Zetec Flywheel
Mondeo 1.6 / 1.8 Zetec clutch plate and cover
Ford Capri clutch release bearing (QH CCT133)
Starter Motor Delco DRS 3468 (Sierra 1.8 CVH, 1988), this is the same as a Lucas LRS 707
Daihatsu Charade alternator,
DIY alternator bracket
Tiger exhaust manifold and 4 >1 collector, Wunoff silencer
Twin 45 DCOE's and Aldon manifold
Scholar Engines shortened sump,
Raceline water rail
GEMS raceline ECU
1.8 zetec escort water pump and groved pulley.
GEMS engine wiring loom, rest of car DIY wiring loom.

[Edited on 3/8/04 by givemethebighammer]

[Edited on 3/8/04 by givemethebighammer]

[Edited on 3/8/04 by givemethebighammer]

quote:

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Originally posted by James
The Duratec is the Ford engine of the future.

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Similar to others from when I converted crossflow to zetec.

New zetec engine. Stage 3.
Mondeo altenator.
Sierra 2.0 DOHC starter.
Standard flywheel and back plate.
CVH friction plate.
Type 9 gearbox.
2 X Weber 45 DCOE.
Weber alpha 2D ignition.
Shorted the sump and pick myself as the newer zetecs have a two section sump where the bottom half can easily be modified.
Standard water pump.
Ford transit engine mounts.
Modified lolocost exhaust at the moment.
Silver top facet pump and filter king.
Fiesta 1.25 oil filter.
Escort expansion bottle.

There is no real need for the race line water rail as this can be done with some SS pipe and a few hoses. Use the standard thermostat.


Thats about it I think. Everyone will do things differently but it looks like a lot of combinations work, especially for the clutch arrangement.

Dave I will be back home next Thursday so if you want to pop in and see what I did no problem. Just down the road in Polmont.

[Edited on 4/8/04 by Big Stu]

My spec from when I did a zetec into Sylva Star conversion. Bear in mind that this was about 5 years ago, so I was making it up as I went along. I would not do it this way now - that's for sure.


1.6 zetec from Escort
Standard zetec clutch cover
1.6 pinto friction plate
1.6 pinto release bearing
type 9 gearbox - the one with the cast pig iron BH
Prop from Propshaft services in Bonnybridge.
Inlet manifold from Burton
2xDellorto 45DHLAs froma scrappy lotus Eclat.
Lucas alternator from a Rover 214 - remounted on the OS with the original bracket.
Original fomoco exhaust manifold with a 3" 90" bend modified and welded on using dissimilar rods.
Section of 3" flexi exhaust.
600mm long x 3" bore ansa silencer with half a cherry bomb stuffed up it ( the cherry bomb is 3" O/D - bingo )
Remote oil filter and cooler.
Dunnell 2D clubmans ECU.
Pinto 1.6 pre engaged starter with 0.75" spacers onto the bellhousing.
Cooling system - just like Stu's, no cast water rails here

apart from the exhaust - which was rubbish- it all worked fine. As I said above - wouldn't do it like that now.

has anyone tried fitting a 1600 cvh sump on a zetec?

Steve Hnz - I've posted photos to my archive.

Big Stu - I had no choice but to use the Water Rail or get a special thermostst housing fabricated - my phptos will show the problem!

Wyn

[Edited on 4/8/04 by lsdweb]

[Edited on 4/8/04 by lsdweb]

Hi zilspeed,

I notice you have used a 1600 zetec along with an inlet manifold from Burton power. Which one was it please?

Also I have called Westfield (as they do a zetec/webber kit) but they weren't sure as to the compatiblity between the inlet manifolds on the 1600 v 1800/2000. Has anybody got any experience with this please as I am trying to get the carbs on pretty quick.

thanks

Carl

I dont think there is any difference between the 1600 and 1800 head externally

It seems the 1.6/1.8 needs less add ons,the 2.0L has a mixture of flywheel clutch combos needs a different water pump and a water rail.

I think i may go for the 1.8 and maybe look for one of the 130 psi engines.

As I'm well into the 'Locost' side of things I'd like to see 'Locost' options for fitting a Zetec........

I believe there is a Westfield installation that uses the stand injection/ecu etc........

Why does the 2.0 Zetec need more fiddling with?



[Edited on 5/8/04 by Surrey Dave]

yup

I'll be going the cheap route as usual

Guys

Drive a two litre before you make a final decision!!!

Wyn

Using the standard ignition system will probably turn out more expensive and time consuming in the long run. There is a way that you can use the DIS ignition system from an escort for about £30 out the scrappies but I am not sure about the details of this.

The standard injection side of things is possible but you need to make a new plenum chamber as the standard one either goes over the top of the engine (which means you would need a huge power bulge) or down the right hand side of the engine (which means you either need to make your car LHD or make a fancy steering linkage).


[Edited on 6/8/04 by Big Stu]

I think i need to read into this a bit more,i didnt realise the original ign system had to be re-worked which sounds a bit wierd as it works in the donor.

I was hoping to get a 1.8 zetec from an orion ghia,this is the 130 psi engine as in the xr3i so should have one over on the 2 litre(or so i've been told)so if i take eng form an escort/orion would the ignition be ok ?

Bob,

Could you not do a 'Mark Allanson Injection Pinto' style mod and therefore keep the injection system?

Okay, so the steering maybe more complex but that's only a case of adding a UJ in isn't it?

If you moved the alternator as well you'll have bags of room!

Atb,
James

James

?

I'm baffled

As far as I'm aware the Ford ECU is also used in the immobilser circuits and as such needs all of the associatied sensors to be in place.
I was going to go down the aftermarket ECU route, Omex, Emerald etc but the £500 plus price tag was putting me off.
I am currently looking at Megasquirt DIY systems which seem to offer just what I want at an affordable price. I have no experience of them yet but the info on the web site indicates a locost, diy adaptable system supported by resoursful individuals.
Hope I'm right, (if I'm not let me know before it is too late)

http://www.bgsoflex.com/megasquirt.html

Mick

[Edited on 6/8/04 by Mix]

The flywheel on the 1600 and the 1800 are the same according to ford (same part No.) So far the seals i got from ford ( sump,rocker c/shaft oil seals) are the same for 1600 and 1800 the head gasket is different because the bore size 4mm difference.

If anyone has a standard alloy sump from a 2.0 ltr would they mind measuring the depth at its deepest end (front) for me please. just want to see if there is any difference in size. The sump on the 1600 is 190mm deep (outside measurment). cheers

Mick,

Nothing to stop you using Megasquirt with a Zetec. It's cheap compared with other aftermarket systems.

There's a few posts about it here. Rob Lane is using it on his 4Age and CairB has done one for his Pinto in practice to soon fit it to a Duratec.

It's about £100 for the kit plus a bit more for the stimulator which apparently is worth having.

It's the route I'll use for my next engine (prob. 2 years away) which will be either Duratec or S2000.

HTH,
James

[Edited on 6/8/04 by James]

quote:

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Originally posted by bob
I'm baffled

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There are two types of 1600 zetec, the E and the S. The S is the one in the Fiesta, focus and fusion, the E is the one in the escort and mondeo. The E is the same basic design as the 1.8 and 2.0, the S is completely different. Hope I got it all the right way round.

Adam

quote:

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Originally posted by James

quote:

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Originally posted by bob
I'm baffled

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I always thought you looked like the inside of my sump!



Anyway, re-reading the posts I just realised you were talking about ignition- I read it at first as injection!

I was trying to say you could move the injection manifold round to the side (as opposed to on top of the engine) like Mark Allanson has done so nicely for his Pinto. He's written a .pdf document as a guide- it's on here in a couple of places.

Anyway, I'm gonna go home now as it's too late for work on a sunny Friday!

James

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quote:

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Originally posted by cdp
Hi zilspeed,

I notice you have used a 1600 zetec along with an inlet manifold from Burton power. Which one was it please?


thanks

Carl

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Dave

2.0l sump is 215mm at it's deepest, (mating surface to base at sump plug,externally).

It may also be worth mentioning that the Escort and Mondeo sumps have the oil reservoirs at opposite ends, (Mondeo one is at the gearbox end).

Cheers Mick

I fitted the bellhousing to the engine last night and the bellhousing sits 10mm lower than the sump. Surely i dont have to shorten the sump if the bellhousing is lower than the sump?

Wyn, magic photos, beautifully clear & very neat job, any others you care to post will be drooled over!
Adam, Would I be right in thinking that a rear sump is a no no, oil starvation under braking & that sort of thing I imagine? so I`ll have to look out for an Escort zetec, definietly harder to find than a Mondeo one out here.

Many thanks Steve

I'll post more photos when I get a chance. The most impressive bit (which I didn't think of!) is the clutch pullrod mechanism - it does away with the hassle of trying to get a cable to fit and bend in a tight space: it's really smooth as well. I'll post photos soon.

Wyn

Another pic of a Zetec in a Se7en. This time running stock injection and in a Caterham SV

Top quality photo zilspeed where did you get from

Right click the pic and check the properties - I've linked direct to the pic. A bit naughty, but it keeps 'our' bandwidth down. .
It's an american caterham specialist that I stumbled upon

Found the site then realised it was american looks good. I have stored the picture as it's the same plenum as the one i intend to use

There are two problems you will need to over come if you want to use this injection. The steering as mentioned and also the diagonal bar that goes from the footwell to the front of the chassis. What injection would you use for this?

Looks like a home made job but will overcome the steering link prob if you have one,also i've seen other builders cut the tube out that runs across a 1/3 of the engine bay.

Re : OE plastic manifold.


I was obviously having one of my 'slow' moments - the fact that it was a LHD car completely escaped me. This fabricated manifold looks much more like the thing for a RHD narrow bodied car. It also has the air intake at the front which has to be better.

Yep air intake looks ok,i was also posted this pic too.
Rescued attachment plumbing2.jpg

That looks like a distributor hanging off the N/S of the block

Actually i'm not too sure its a zetec,i was looking at the plenium at first.

Don't think it is a zetec oil filler is in wrong place?

That's a Toyota 4A-GE
Just studied the position / angle of the dizzy and the shape of the cam cover.

A friend has one in his sprint car running on carbs and a ford dizzy for simple sparks. Goes like a whippet.

still gathering info here on zetec and box combo's price effect and all that.

Anyone else with any input much appreciated ?

Clutch setup tried to get a friction plate today cant find anyone who sells the parts individually only kits. Mind you i got a price for friction and thrust bearing £47 or 3 in 1 kit £44.99

eariler on there was mention of a QH CCT133 release bearing?? what capri is this off?

Im most intrested in this post aswell, as im already collecting the bits for the job..
I have already

1993 2ltr zetec 75 k
R1 motorcycle carbs (quad 40mm)

Bogg brothers have started on the manifold today

1.8 l escort flywheel
1.8 l escort sump+pick up
mt75 gearbox from 2ltr Dohc..

I plan on using a good zetec clutch,as for the thrust bearing it will depend on how much cash ive got on weather it will be a home made spacer on a new trust bearing or the westfield one....

Question?????
Does the sump need cutting ? I understand that a cut and shut sump is about 165mm and will cost another £200 but for that Ill only gain 15mm or so ?Can I not just put a bulge in the bonnet like the avon?And raise the engine just enough to get the ground clearance?

Question 2????????
What about ignition?? I was going to have ago at megajolt ,but I can not find the info I need to get the bits in this country?? can anybody help??Or if I can find the cash how good/user friendly is the emerald setup??
I would also like to no other peoples experiance on using the zetec.....

You ask about price...
well my first motor was the 1.8l from an orion this was £50 on ebay..This seems to be the going rate or about £100 from a breakers guaranteed.....

This turned out to be buggered so I sold the bits on ebay(as faulty) for £55 and was still left with flywheel /sump/rocker box/ignition coil breather and lots more

Ive just borght on friday my 2ltr from my local breakers that also surply Tiger..This was £200+vat...You will pay over double for the extra 200cc .On paper the bhp does not look worth the extra, but it has lots more torque and this gives your acceleration...having owned mondeo's and escort's/orion's the heavier mondeo will kill the escort of the lights every time and is well worth the extra cash..

Old thread but worth a read,i've been out of action in the garage for the last couple of months (knee problem) but the pinto was outed in october and i have all the parts needed bar an air filter to fit the zetec.

I've used all the information from this thread to gather my parts so big thanks to everyone for there input.

Many many different variations on plumbing can be a tad confusing,but hey if it works it works.

Any more info and pics though can only be helpfull to others.

My car is not on the road so I do not know how well is my engine. However I used mondeo ecu: it is quite simply to have it work if you have "electri schematic". If you not have it let me know I will scan and email.
Engine starts also without maf, lambda sensor, and other sensor. So you can get your engine running quit easy like I had.
Rescued attachment Motore1649.JPG

If this is the ultimate guide then watch the crankshaft pickup.

If the engine was from an automatic the crankshaft pickup need to be changed to the manula one when you fit the manual flywheel. Part cost £5 from FORD. need to be fitted before fitting fly wheel.

Do you mean the crank position sensor (CPS)

Loads of pics from my xflow-zetec conversion in the Fury gallery on gallery.cantcatchme.net

I took the easy route....
Rescued attachment Copy of Picture 004.jpg

quote:

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Originally posted by bob
James

I'm still baffled,you didnt re-read the posts far enough.
Its zetec and ignition for it,the pinto will get binned.

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Hello Mike

I did look at trying to use the original plenum as the 1.6/1.8 uses a slightly smaller one in bulk than the 2 litre,and it is possible to fit the 2 litre throttle body on the 1.8 plenum.

Still to big though so i looked at home made plenums,with most of them looking like a dogs dinner and some not working efficiently and ending up on ebay i decided on bike carbs for now.

trust electrical do a suitable low-line plenum....

Cheers steve

I've gone the fireblade carbs route for now,Bogg Bros are making the manifold now so i should have it by the end of the month.

I've also some zx6 TB's which if they split i might have a go with maybe next year, although there is always something else for me to spend my allowance on

I am getting along quite well with my conversion but though I should advise caution on the inlet side.

I have had to shorten my inlet manifold as there was not much gap between the rear TB and the brake Master Cylinder.

I will soon be sorting out the spaghetti wiring of the MegaSquirt.

Don't worry, I do intend on wrapping the other primaries but I ran out of wrapping.







[Edited on 22/1/07 by TangoMan]

Managed with some alternations to get a black top into an Avon.
Rescued attachment grondplaat Avon 009.jpg