Hi all,

Apologies if this has been covered before but I could not find what I was after;

Here goes,

1. I have a 98 onwards 2.0L Zetec engine and wanted to retain the original inlet manifold and throttle body, what is the most cost effective way of managing this for maximum gain? I have found a kit by Alpha (Webcon?), which is specifically for this task but it is quite expensive at approx £1050. I do not have the original ecu but all the sensors, induction system and coil pack are with the engine.

2. Can the sump be modified and if so what is required taking into account keeping oil surge to a minimum?

3. I have a 1990 2.0l GLSi Sierra from which I would like to use the MT75 gearbox. I was considering a 1.8l Zetec flywheel coupled with a 2.0l clutch but I have heard that a modified thrust bearing is needed and up rated springs. Is this feasible and are there any other considerations I should take into account?

4. Can the Sierra starter motor be used?

Many thanks in advance for any help / advice given.

Best regards,

Rich

Can't help with the inlet, but Gearbox clutch yes.

There are many ways to do this, none right or wrong, here's what I've done:

Clutch, redrilled the 1.8 flywheel to take the sierra 2.0 DOHC clutch, this clutch matches the gearbox, and I had a brand new one anyway, uses all standard dohc parts including the thrust bearing.

Sump/Starter, I have a QX1220 starter, sierra CVH, pics of the sump mods for mondeo - all ally, and focus - ally tin attached. Its not a 7 type car so shortening wasn't needed.

As well as the attached pics there are pics in my archive of itbuilt up.

[Edited on 3/4/08 by r1_pete]

[Edited on 3/4/08 by r1_pete]
Rescued attachment clutch on.JPG

ally
Rescued attachment Ally sump.JPG

ally tin
Rescued attachment ally tin sump.JPG

i have a 98 2.0l blacktop mated to an mt75 box, i am using the 1.8 zetec flywheel and clutch and a modified release bearing which can be supplied by westfield. i am running megasquirt along with the original throttle body and fuel rail and injectors. i could not use the original inlet manifold as there is not enough room as it fouls the steering arm and the side of the chassis rail so have fitted a GRIFFIN POWER inlet manifold which should allow 150/160bhp, cost wise about £200 for megasquirt,£200 for manifold

I would avoid the Webcon kit as it can only be mapped or changed by a dealer. Emerald and most others are very user friendly and easy to use, they can also supply loads of maps for free to get you started.

Thank you for all your replies, some very useful information.

Cheers

Rich