benje
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 posted on 31/3/05 at 03:46 PM |
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Xflow to Zetec Help Required!
Hello people,
I need a little help in the conversion of a 1690 crossflow to a Zetec. I've had a good serach but have yet to find any definitive answers!
Ok, I've been offered a 2.0 zetec from a 95 Mondeo. Now before I purcahse this I need to make sure the conversion isnt going to cost me
millions!
So far I gather:
1)Sump will need modifying, i.e. the big bulge chopping off, is this easy enough to do ? I have access to a mig welder etc!
2) I was planning on running the standard injection system but it seems firstly the inlet manifold will foul the steering column. Secondly being a
xflow on carbs I only have the fuel pump which is driven off the cam available, I'm assuming to run the standard fuel/ignition system I would
need a suitible fuel pump, and also a return line and vent in the petrol tank?!?
3) If I got the standard system to work, have they got an immobiliser etc built in? which would need to be defeated before the engine would start?
Failing this I see a few people run motorbike carbs which seem simple enough i.e. I would only need a new fuel pump and not a return line /swirl pot
etc. Any particular types recommened? And where can you purcahase new jets for them? or get them rejetted at a reasonable price?
Finally does the 2.0 mondeo use the EDIS system, so if I do use carbs I can use the likes of megajolt etc to provide igntion. Has it got the necassary
36 toothed wheel already or would I need to source one?
Thanks
Ben J
P.s does the Zetec mate upto a type 3 or 4 box (IIRC from a MK2 Escort standard 4 speed job with integral bell housing?)
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benje
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| posted on 31/3/05 at 03:50 PM |
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Another thing I forgot, I assume my twin 40's will be too small for a 2.0?
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big_wasa
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| posted on 31/3/05 at 07:00 PM |
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Lots of questions
My chosen motor is the zetec ,although I dont have the car to put it in yet,Im doing it backwards collecting the donor parts first and recoditioning
them..
The sump from the 1.8 escort is better than the mondeo and is very cheap (sold one on ebay last week for £13.50) money no object would be the raceline
unit at £400 (before some one says ,Im not counting dry sump conversions) and some where in between is the Scholar Engines sump at £150+vat which
is what ive chosen.Forget welding your own unless your a pro it will leak like a siv if you use a mig/mag...
Edis 4 only came on the automatic mondeos but you can find it on lots of other Fords but the megajolt setup does not seem to be that easy to get hold
of and anything elts is going to cost the thick end of £400.
Im running mine on bike carbs .You can use the standard induction, pre 95 engines will be easier to install . The ecu contoles everything and the
latter ones are more complicated and harder to use...max bhp with this will be 140 ish but change to carbs or throttle bodies and you will push
165-175 bhp ish..
The zetec can be a cheap engine but with a few trick bits here and there it can soon mount up to £2.5k as im finding
out
 
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Danozeman
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| posted on 31/3/05 at 07:03 PM |
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Twin 40's should run it mate. I would sling the standard ecu as it has an immobiliser in it. And run megasquirt and megajolt to fire the
injectors and ign or bin em and run your 40's. Ul need either an esc module off an older ford or use an aftermarket ignition.
Im putting an 1800 zetec in mine and running esc for the time being and bike carbs for fuel.
Much simpler to run carbs imho.
Dan
Built the purple peril!! Let the modifications begin!!
http://www.eastangliankitcars.co.uk
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big_wasa
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| posted on 31/3/05 at 07:03 PM |
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scholar sump
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Danozeman
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| posted on 31/3/05 at 07:05 PM |
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That looks a tidy sump wasa. Will they chop my standard one do u reckon? they is only just up the road from me!!
Dan
Built the purple peril!! Let the modifications begin!!
http://www.eastangliankitcars.co.uk
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benje
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| posted on 31/3/05 at 07:29 PM |
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Thanks for the info people.
As for the megajolt I can get all the components easy enough and can also get some one to make me a PCB (hopefully) so that should be the ignition
side of things done (assuming the mondeo flywheel has the 36 tooth wheel on?!?)
For fuel then, dump the injection and I think I'll go for the motorbike carbs idea, any particular choke sizes I should be looking for? Saves me
having to modify the fuel tank for the time being!
Few more questions! Engine mounts are they massivly different from a xflow?
And does anyone know what clutch combination I would need to mount it to a type 2 4 speed box? According to burton power the input shaft is 7/8” x 20
whilst a type 9 is 1” x 23 so has anyone attempted this combination?!?!
Cheers
Ben
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big_wasa
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| posted on 31/3/05 at 08:20 PM |
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Forgot to say the sump is on exchange bassis..and comes ready baffled and with modded pickup pipe..Only complaint was that it came sprayed in black
enamel.This wasnt a problem in itself but it hadnt dried properly and stuck to the box I put it in on the way home If you want any pics just ask or
I will put them in my archive when I get round to it..
The zetec flywheel will work fine for megajolt just make sure you get the manual flywheel and sensor housing not the automatic...Again escort flywheel
is better as its lighter..I managed to pick up my best bargain yet which was my fly wheel........
As for gearbox Im using the Mt75 from the dohc like westfield use...You then use the standard zetec clutchplate/backplate and an extended(westfield
£55) release bearing.Having used both a type 9 and the mt75 boxes I much prefer the mt75 its a much beter box and moving the gear stick is very
easy......And it will take loads of power
The only down side is the box is a touch bigger but it is all alloy and ment to be lighter.....
You say you can get mejagolt stuff easy ??? Please share because I bloody can't..The ready blown eprom is what I can't find in
blighty
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Danozeman
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| posted on 31/3/05 at 08:31 PM |
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I wouldnt use the type 2 box.. Type 9's are cheap enough to get..
Dan
Built the purple peril!! Let the modifications begin!!
http://www.eastangliankitcars.co.uk
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big_wasa
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| posted on 31/3/05 at 08:40 PM |
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Down to pearsonal choice?
Mt75'3 are very cheap Im going to pick another up tomorow for £30 or Ive got a one in a car with a years mot for £50 but the cars no good with
out it
Have you considered how long a type 9 will last with 175 bhp and nearly as much torque up it Thats nearly double what it was designed for
[Edited on 31/3/05 by big_wasa]
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paulf
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| posted on 31/3/05 at 09:19 PM |
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I know have my Homebuilt Megajolt working , I built a programmer for the processor and after lots of trial and error can now flash blank chips with
the bootloader and s.19 files .
If you want to send me a blank chip I can flash it for you or can add a chip to my next Farnells order if you are not desperate.
All the other parts are easily obtainable .
Paul.
quote:
Originally posted by big_wasa
You say you can get mejagolt stuff easy ??? Please share because I bloody can't..The ready blown eprom is what I can't find in
blighty
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big_wasa
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| posted on 31/3/05 at 10:08 PM |
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Nice one How well is it running Have you found a good map yet, whats a chip going to cost me could with a couple to play with...
Dont surpose your taking it to the show on sunday would love to have a look and a chat
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benje
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| posted on 31/3/05 at 11:02 PM |
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Well I'm an electronics engineer by trade so the megajolt should be easy!! (famous last words!!!!!)
I really wanted to avoid moving to a type 9 box as from what I can tell, it's longer and the mounting position is further back than a type 2
box, which goes onto adding cost!!!! It would also need a modified propshaft AFAIK, as I'm running a escort rear axle (not IRS like the
sierra)
Back to the fueling again, would twin 40's really be enough? Looking at a few websites the maximum 36mm chokes will really be too small for 2.0
litres, so if I do go for motorbike carbs are jets readily available like they are for the webers?
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benje
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| posted on 31/3/05 at 11:20 PM |
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Just done a quick parts pricing on megajolt components and they shouldnt be more than £20 hopefully, so megajolt is a definate!
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big_wasa
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| posted on 1/4/05 at 08:50 AM |
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Back to the carbs...I payed £60 for a a set of Quad 40mm r1 bike carbs 12000 from new on a 98 plate...Bogg Bro's stripped cleaned and re jetted
them for about £50 They said that they are very easy to set and having done a few now .They can set it to run on the bench with just a few tweakes
needed when its on the road ,to balance them ect...
They look the b*ll*x but for the money they have cost me I proberly would not been far of webber 45's??????That said im told they are a right
pain to set up and I do like to be differant..... If you are good with your sparky bits why not go fuel injection with bike tb's....
When a bike carb slide is open they are straight through so 40mm means 40mm unlike the webbers.......
Carbs also mean getting an engine made befor aug 98 which isnt hard...But by the time you have added in a strip/check and clean you can buy a year
2000 engine with only 20k on the clock that just needs a steam clean and fit.....
I was quote £600 by fords yesterday for a full gasket/oilseal and bearing set
As I told him burtons it is then
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paulf
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| posted on 1/4/05 at 09:13 PM |
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Ive not driven on it yet, I have just taxed the car today and been out for a run on the old dizzy system tonight. Im working until Monday so will have
to wait until then to hook up and try the megajolt on the road.
Ive been playing with the car tonight , didnt get in until 7.30pm and have just come in from the garage for dinner.I cant wait until Monday for a good
drive and play with the ignition.
I think the microcontroller chip is about £5.0 from RS. I managed to get mine as free samples. The PCB works out at about £9 with postage from the
states and the other parts about £15 or £20from RS or Farnells.
Paul.
quote:
Originally posted by big_wasa
Nice one How well is it running Have you found a good map yet, whats a chip going to cost me could with a couple to play with...
Dont surpose your taking it to the show on sunday would love to have a look and a chat
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