After taking out the leaky old Ford Crossflow it has been replaced with a low mileage 2.0L Blacktop Zetec from a Ford Cougar.
Cleaning - Painting - Chop Sump - lots of paraffin - took most of the time.
NODIZ ignition straight swap from Crossflow.
Twin 40's onto a Zetec Manifold from Crossflow.
Used old coolant hoses to get it up & running.
Crossflow exhaust cut n shut to fit - (The rust is what the Heat Wrap has done).
1800 Flywheel & Mondeo Clutch Ctt133 thrust bearing.
Sump Gasket - Timing Kit - Reinzosil Sump Sealant.
Sump to ground is 3.75 inches.
Cam cover removed & is just in contact with the nosecone.
Tight fit top to bottom.
Mann W712 Oil Filter fits perfect.
Used overhead Winch / pully to remove & put new engine in which was very easy.

Click here .. for a video of start up

Excuse the crappy welding & Most pipework is temporary & will be tidied

That must have been a really satisfying job. (He said enviously).

Is your chassis as per Uncle Ron's book? In particular, is the height from bottom chassis rail to top rail same as book dimensions? Am particularly interested, as I also aim to replace my old crossflow with a Zetec. Just wonderin' 'bout the clearances you get beneath your bonnet & nosecone. Watched video, and noted how close to nosecone were the cam pulleys. Did you have to modify your bonnet?

Great start up and I hope he doesn't forget to find room for the cam wheel cover...

Ron's Book Chassis - do it yourself for £250 lol .
Left off the cam covers like some people have - gives more ground clearance.
The camshaft cover has a nice big lip on top so it just touches the nose cone.
Made an idler pulley to adjust the belt tension - The alternator will be fixed solid.

But what you want to know is how it compares? Well ..

I went round the block to test the clutch & throw the oil about to check for leaks..

OMG ... this is 'THE' car I wanted to build..
The power difference is fabulous..
Its smooth - sounds good - launches & seems a lot more rapid compared to the Xflow...
If it feels this good now then I cant wait to get it on a rolling road tuned!

The time & money wasted on that disappointing Xflow lump!
I would highly recommend doing the swap asap .. -

p.s . Amazingly the carb air filters come through the bonnet in the same place! No need to change anything!

Bits:
2.0L Zetec 61K complete with 1800 flywheel & Random pipes £200
Starter Motor £20
Mondeo Center & Pressure plate £30 inc p&p
Thrust bearing ctt133 £19.95
Spiggot bearing £8.00
Accuspark 45 amp 18ACR alternator £39.95
Reinzosil Gasket / Sump Sealant £8.49
SUMP GASKET FORD ZETEC £28.62
IGNITION COIL PACK *BRAND NEW* £14.00
Zetec Inlet Manifold For Twin DCOE £77.02
Ford 1.8 2.0 ZETEC EXHAUST Manifold
Zetec Cam Timing Belt Kit £34.99
Flange Plate 8mm £22.60
Stainless Steel Cutting Discs Metal 115x22x1mm Super Thin Angle Grinder £5.16
Total: £500+ approximately
(also welding wire - Gas - 5/30 oil - Antifreeze - Flywheel Bolts )


[Edited on 18/4/14 by johnemms]

Friend of mine left the cover off, 'as some people do' and guess what, got a pebble under the belt and it cost him a rebuilt head and a piston...

I'll probably figure something out with protecting the cam belt..
But ground clearance is prime concern at the moment..
There is 'some' give in the cam belt tensioner..
If I was on a track day then gravel traps would be a serious concern.
But I can spanner it out in 30 minutes & swap it for £150+

Nicely done mate

remember when I first drove my blacktop after pulling the crossflow out....had been running for a year on ancient tyres and found them fabulous for the power I had...just the right amount of drifty...with the zetec, they'd scared me pantless before I'd gone 500 yds...decent boots were purchased the following day...

Hi Just doing the same the engine swap to mine seen loads of mentions of changing the water pump Why?.
Did you make your own engine mounts, did you blank off the crankshaft breather and fit the catch tank from your crossflow set up.
So many questions hope you dont mind,but love the look of your set up, thinking of using nodiz pro ecu and I have some zxr9 carbs should add a couple of more bhp.
Thanks Mike

Hi, Just doing the same the engine swap to mine got a zetec 1.8s 130 bhp engine lower sump e.t.c seen loads of mentions of changing the water pump Why?.
Did you make your own engine mounts, did you blank off the crankshaft breather and fit the catch tank from your crossflow set up.
So many questions hope you dont mind,but love the look of your set up, thinking of using nodiz pro ecu and I have some zxr9 carbs should add a couple of more bhp.
Thanks Mike

First run out makes it all worth while doesnt it
Ive just done cvh to rs1.8 zetec on bike carbs
Totally different car now,dont miss the webers at all
I used a cvh efi flywheel,drilled out the bolt holes to 11mm and used a mondeo clutch
its only about 6 kilo so revs like a bike too

Used old crossflow setup - drill out pcv valve - up to rocker cover - T piece - No filter on can as if it gets oil soaked it acts like its blocked and creates back pressure.. So blue pipe venting to floor - Lots of hard driving - only vapour in can no oil ..

catchcan 2


catch can