dave1888
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| posted on 2/8/04 at 07:15 PM |
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Zetec the difinitive guide
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 ?
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lsdweb
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| posted on 2/8/04 at 08:10 PM |
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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
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Steve Hnz
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| posted on 2/8/04 at 10:48 PM |
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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.
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James
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| posted on 3/8/04 at 08:09 AM |
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quote:
Originally posted by dave1888
It seems the zetec is the engine of choice for the future ?
The Duratec is the Ford engine of the future. I'll be looking at that as a possible upgrade path for my Locost in a year or two...
... if I don't go for an S2000! 
James
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dave1888
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| posted on 3/8/04 at 06:00 PM |
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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
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Browser
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| posted on 3/8/04 at 08:31 PM |
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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?
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givemethebighammer
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| posted on 3/8/04 at 10:41 PM |
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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]
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locost_bryan
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| posted on 4/8/04 at 02:17 AM |
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quote:
Originally posted by James
The Duratec is the Ford engine of the future.
It's Mazda's MZR engine by another name, but since they're part of the Ford group... 
In the US it's fitted to the Focus and the badge-engineered Ranger pickup as a Duratec, and to the Mazda B2300 pickup and Mazda3 and Mazda6.
So, the good news is that there is an out-of-the-box 165hp 5-speed rear-drive setup
... and in the Mazda6 it's got a very nice sporty sound when working hard.
Also rumoured will be fitted to next gen MX5...
Bryan Miller
Auckland NZ
Bruce McLaren - "Where's my F1 car?"
John Cooper - "In that rack of tubes, son"
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Big Stu
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| posted on 4/8/04 at 08:40 AM |
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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]
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zilspeed
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| posted on 4/8/04 at 02:28 PM |
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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.
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dave1888
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| posted on 4/8/04 at 06:41 PM |
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has anyone tried fitting a 1600 cvh sump on a zetec?
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lsdweb
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| posted on 4/8/04 at 08:20 PM |
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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]
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cdp
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| posted on 5/8/04 at 09:49 AM |
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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
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dave1888
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| posted on 5/8/04 at 07:58 PM |
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I dont think there is any difference between the 1600 and 1800 head externally
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bob
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| posted on 5/8/04 at 08:35 PM |
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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.
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Surrey Dave
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| posted on 5/8/04 at 10:03 PM |
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Cheapskate Zetec.........
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]
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bob
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| posted on 5/8/04 at 10:17 PM |
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yup
I'll be going the cheap route as usual
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lsdweb
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| posted on 5/8/04 at 10:46 PM |
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Guys
Drive a two litre before you make a final decision!!!
Wyn
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Big Stu
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| posted on 6/8/04 at 07:38 AM |
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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]
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bob
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| posted on 6/8/04 at 08:00 AM |
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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 ?
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James
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| posted on 6/8/04 at 09:41 AM |
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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
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bob
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| posted on 6/8/04 at 10:01 AM |
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James
?
I'm baffled
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Mix
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| posted on 6/8/04 at 04:44 PM |
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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]
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dave1888
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| posted on 6/8/04 at 05:07 PM |
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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.
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dave1888
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| posted on 6/8/04 at 05:10 PM |
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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
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