Ford Zetec - On A Budget
Many people are put off installing the Zetec because of the higher costs involved during installation. With this page, I hope to remove those myths
and show that a Zetec can be installed for significantly less than originally thought.
Engine
Whilst the 2.0 litre engine may provide the most power from the Zetec-E engine range, don't discount the lower capacity variants as the 1.6 and
1.8 models are generally a lot cheaper from a scrap yard than the 2.0 litre engine. For an early 1.8 litre engine, you should be looking at paying
around £250 - £300.
Fuelling
Whilst the engine originally comes with injection, getting this to work without major problems becomes expensive. A far cheaper solution is to
purchase a manifold for twin DCOE style carburettors, and then a second hand pair of 40mm Weber DCOE or Dello'rto DHLA carburettors. This should
cost around £200.
Ignition
As the Zetec doesn't have a distributor, you will need a 'black box' to control the ignition timing. Fortunately, another engine in the
Ford range comes to the rescue. The later 1.4 and 1.6 CVH engines, running on a single carburettor and featuring a coil pack (rather than distributer
and coil) come complete with a 'black box' (actually silver). This connects to the coil pack, crank position sensor and a couple of
temperature sensors and provides an acceptable 2 dimensional ignition map for running the Zetec.
(The late square shaped Escort 1.6 Ghia the one which went up to G or H reg) running a single downdraught carb, but this is the same as used on other
carb fed 1.4 or 1.6 CVH Fords of similar vintage including the Fiesta, Escort and Orion. )
To use this system, you will require the electronic control box, the engine loom complete with sensors and any additional small modules attached to
it.
Firstly, locate the control box. This is around the size of 2 cigarette packets and is located on the nearside inner wheel arch. To remove the loom,
find the round plug which connects it to the main car loom and cut off the wires on the car side, leaving a few inches spare to solder this plug to
your kit car loom. This should leave you with a brown, green and black wire. Take all components attached to the engine side of this loom apart from
the coil pack.
Fit all components to your car, ensuring the ECU and any external control boxes are located on aluminium or steel surfaces to help dissipate any heat
generated. The crank position is located on the flange behind the flywheel on the exhaust side of the block, you can discard the one from the loom and
use this one instead. You can then wire the car side of the 3 pin connector to your cars existing loom. Connect the brown to earth, black to a
positive ignition switched supply and green to the rev counter input.
Flywheel and Clutch
It is possible to use the flywheel and clutch assembly from a 1.6 or 1.8 litre Zetec engine. These are lighter than the 2.0 litre model and also use a
smaller clutch with the correct number of splines for connection to a Type-9 or MT75 gearbox. In addition to the clutch, you will require a clutch
release bearing from a 2.0 OHC (Pinto) Sierra with a Type-9 gearbox.
Starter Motor
When using the 1.6 or 1.8 Zetec flywheel, you will need the standard starter motor as used on the 1.6 or 1.8 CVH Sierra with a Type-9 gearbox.
Sump
The sump will need shortening. With appropriate equipment, you may be able to do this yourself, but the cheapest option is a cut and shut sump by
someone like Westfield. Due to the porosity of the original casting material, this may well leak a little but this is by no means disastrous.
Exhaust
Finally, you will need an exhaust. A stainless steel exhaust system isn't cheap but is a worthy addition. If this cost cannot be covered. The
standard manifold can be used. This can then be linked to a custom exhaust made from standard steel exhaust tubing, though this will require welding
skills to complete and won't last as long as a stainless steel item.
Could at least credit the guy..
http://www.zetec-cat.co.uk
Cheers
Good info.
I suspect engine prices are even cheaper now as so many in scrap yards now and very few being sold as Ford will supply a new engine for just under a
grand exchange, and they are reliable.
I'm not sure the standard release bearing will work, Westfield fit a modified part, I fitted a Dunnel clutch which uses standard bearing and arm
(don't know part number though).
I got exhaust made up for £350 in stainless which I suspect would be the same for any 4 pot, just need to shop around.
I fancy using the complete inj system with the zetec. any thoughts?
Me too (standard Ford injection). Where can I expect problems?
About the clutch release bearing; I understand that I need the Capri part: CT133 Quinton Hazel. But my supplier doesn't have QH numbers, and it
turns out that the Capri has had three different release-bearings, all pretty different in diameter or depth. Any clues as to which one I need?!?!?!
Dave good luck - have you seen the thing. Pretty massive and unweildy. Plus you'll need to run the original ECU or do something to allow idle air
passed the throttle body butterfly using the bypass valve. Doesn't seem like an easy solution. I've got the inlet manifold sat on my desk
here...
Cheers
Even though I prattle on about having enough power with the xflow, I would imagine I will do the zetec conversion sooner rather than later. I'll stick with the carbs from the xflow, get an exhaust manifold flange and weld it to the lolocost xflow manifold - just like stu's ;-) - and run ignition via an edis and megajoltlite - junior. Very simple, very cheap and all the data is available online. I reckon a complete mondeo will be cheaper than buying a zetec from the scrappy. 3D ignition mappable via laptop for around £60 including an edis from the N/S inner wing of an injected ford from 90-95. That could ultimately lead to throttle bodies and it's all simple enough for my little brain to cope with. The nuts and bolts of the zetec conversion I have done before - I just won't have to pay 400 quid for sparks this time. This internet is a wonderful thing. here's a proven installation of this setup in a bloke's spitfire. Megajoltlite Junior
quote:
Originally posted by SeaBass
Could at least credit the guy..
http://www.zetec-cat.co.uk
Cheers
Decisions decisions been reading a bit about the zetec se 1.6 all ali engine ford have developed with yamaha. As fitted in fiesta puma and focus they
recon a good engine very happy at high revs and very light around 85kgs compared to zetec 115kgs and pinto 135kgs also inlet and exhaust are on the
same side as pinto. The efi plenum and gubbins isn't that big is it ? bulkier than twin 45's yes but not much wider. Going to auctions
tomorrow night so hopefully i will come back with a donor vehicle of some suitable description
Different bellhousing though as far as I'm aware.
Yes you need a custom bellhousing cost £200 but you dont have to replace the sump so theres a saving.
sump welded for around twenty bucks @ali specialists in Glenrothes the did quad bits for me a while ago and they arnt expensive if you ask nicely.
Injection on the zetec is not that hard to connect up as long as you keep it Standard.
Look at www.xr2zetec.co.uk