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ZetecVan 2.0

Zetecs Into RWD Fords

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Either go for a 1.8 or 2.0 Zetec. The smaller CC engines aren't worth going for due to the cost of the conversion compared with the power you'll get. Look on the exhaust side of the engine block for a 1.8 or 2.0 cast into the side.

 

Water Rail

You need the water rail from either Retro Ford or Dunnell. In the Anglia, the Dunnell fits without you having to cut the bulkhead. It also looks nicer.

 

Sump

Comes in either front or rear bowl, depending on your car. If you need a front bowl sump (eg: Anglia), you can use an Escort 1800 Zetec one. The Retro Ford sumps come with a modified pick up pipe and dipstick.

 

Starter

The one to pick is the Granada 2.0 DOHC starter. If you're using a 2000E box, the starter is on the O/S so you need the automatic version (the solenoid is on the opposite side of the starter.

 

Engine Mounts

You can buy these from Retro Ford. They come in either World Cup X Member or standard types.

 

Water Pump

If you're using a 2.0 litre Zetec, you'll need to change the water pump to a 1.8 litre one. Buy it from Ford. I've had problems with the cheap repro ones you can get on ebay.

 

Alternator

You'll need an alternator fitting kit from Retro Ford.

 

Exhaust Manifold

You can buy Escort ones by Ashley. If you have an anglia with steering box you'll have to modify it so it fits. Alternatively you can buy one that fits nicely from 105 Speed .com

 

Inlet Manifold

You can buy these from Burton.

 

Carbs or Throttlebodies

The choice is yours. TBs are a bit more expensive. Both need an ECU to run as the Zetec doesn't have a distributor. If you want to run injectors you'll need run that does that too.

 

ECU

Dunnell, Omex, DTA and Emerald are popular after market ECUs. Prices are around the £550 mark. You can also build one yourself with the Megasquirt for around £150.

 

Gearbox

Zetecs can bolt up to a type 9 or three rail 2000E box. Most people go for the type 9 because of the 5th gear, but in an Anglia there can be complications with the bellhousing fouling the steering arms so stick with the 2000E. However, Neil at 105Speed.com has recently made a type 9 bellhousing which solves these problems.

 

Depending on your car, you may also have to fit an enlarged gearbox tunnell to fit the type 9.

 

Clutch & Flywheel

This depends on the box you use. You'll need to use a 2litre pinto clutch cover but also need your flywheel redrilled to accept one. You need a 1.8l Zetec flywheel. Retro Ford do exchange flywheels already modified.

 

The clutch depends on which gearbox you use. They have a different number of splines.

 

Don't forget the spigot bearing for the end of the crank. Get it from Burton. It's cheaper.

 

If you've got an Anglia you'll need to get a release bearing spacer kit from 105Speed.com

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the above list is more like an advert. :sad:

 

sump. sierra 1.8 cvh can be easily modded to fit and the oil pipe goes strait on.

 

water pump. you need an ESCORT ITEM. (ribbed pulley)these rotate the other way , tho a std mondeo pump (smooth pulley)with an escort pulley going the wrong way will still reputedly pump enough due to its design.

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Have a go at modding and fabricating a few bits yourself, its fun and you can save a shed load of money. when I fitted my t9 to my Cortina back in it's x-flow/steering box days I just took the common advise and packed the engine up by a few mm til it cleared the arms. I have run my water pump both ways (before and after PAS) and there seems no difference in the cooling (engines a KA which i think is mondeo) but with PAS i think it's going the right way now. I know most people will fit a zetec to get the max power out of it but for those just wanting a cost effective engine replacement with a reasonable power boost i can recommend starting off with the ford standard ecu and injection.

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Anyone have a modified wiring diaagram to fit the zetec into a mk1 Escort.

 

I found it interesting reading saying to use the standard equipment to start with.

 

Im looking at doing the conversion as cheap as possible i was given a 1800 zetec with a cvh sump marked up to be cut to clear the crossmember when i bought the car, what else could i get away with regarding ignitio, ecu etc ?

 

Did anyone watch Chop Shop last night where they fitted a Mondeo 20 into a 1991 Xr2I ? they didnt seem to use many trick parts to get that one running !!!

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Anyone have a modified wiring diaagram to fit the zetec into a mk1 Escort.

 

I found it interesting reading saying to use the standard equipment to start with.

 

Im looking at doing the conversion as cheap as possible i was given a 1800 zetec with a cvh sump marked up to be cut to clear the crossmember when i bought the car, what else could i get away with regarding ignitio, ecu etc ?

 

Did anyone watch Chop Shop last night where they fitted a Mondeo 20 into a 1991 Xr2I ? they didnt seem to use many trick parts to get that one running !!!

 

I used the wiring diagram in a haynes manual (mondeo) to wire mine up. I have 2 ecus (one as a spare) which are non pats 115 spec (BLIP and BLOB £15 each). It's easier to use the mondeo ecu as it has ingition control on board rather than using edis. Plug all the sensors to the ecu using a 93 mondeo wiring loom and add power supplies to the sensors from the haynes diagram. You need a lambda sensor in the exhaust and high pressure fuel to the rail but (and this is the clever bit) when you start it the ecu will set itself up without the need to go to a rolling road. If at a later date you feel you need more power you can rechip the ecu (unichip £600 or megasquirt) and tune away(theres a guy on a mondeo forum with a 180bhp printout on the standard throttle body). Seems like a lot of work but no more complicated than aftermarket fuel and ignition setups.

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Im not worried about actually doing the wiring as im an Auto electrician, i suppose its just that im used to working from diagrams !!! Good tip on the loom and ecu to use, thats the sort of info i would like to know.My car is up and running at present so im not in a rush and want to obtain all parts needed 1st.

 

Has anyone manage to use the whole throttle body and manifolds from a standard car will they fit under the bonnet ?

I was give a running but rusty 1600 Fiesta si on an M plate and was going to break it for the parts is this worth doing or should i just look out for a Mondeo ?

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the above list is more like an advert. :sad:

 

It's just a suggestion so those who don't know how to or don't have the equipment to modify sumps can get the bits from.

 

water pump. you need an ESCORT ITEM. (ribbed pulley)these rotate the other way , tho a std mondeo pump (smooth pulley)with an escort pulley going the wrong way will still reputedly pump enough due to its design.

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Im not worried about actually doing the wiring as im an Auto electrician, i suppose its just that im used to working from diagrams !!! Good tip on the loom and ecu to use, thats the sort of info i would like to know.My car is up and running at present so im not in a rush and want to obtain all parts needed 1st.

 

Has anyone manage to use the whole throttle body and manifolds from a standard car will they fit under the bonnet ?

I was give a running but rusty 1600 Fiesta si on an M plate and was going to break it for the parts is this worth doing or should i just look out for a Mondeo ?

 

Dont bother with the 1.6 engine, there only 90 brake as standard and you'll really struggle to get and more out of it due to the small valve sizes

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The mondeo plastic manifold fits my cortina You may have issues with the servo if you have one. Or you could use the over the head manifold off an escort. i will add a piccy of my modded cvh sump the wings increase capacity from 3.5 to just over 4l and provide a dipstick hole.

cortina043.jpg

cortina041.jpg

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Is anything else worth keeping from the Fiesta ? if not ill sell or swop it for a mondeo !!

 

Zetecvan 2.0

I understand about your shopping list idea and its because you have done this that i have posted here. I did mods to these cars 25 years ago and sold my last Mexico about 8 years ago (for £2500) after having it 10 years and a complete rebuild XRU345K not sure where it is now but its still taxed !!

 

I am completely new to the zetec scene.I know nothing about how to go about fitting one to these cars and a "shopping list" is exactly what im looking for, im a cheap skate and / or would like to keep the cost's down by using my mechanical electrical skills as im very lucky to have my own workshop and work on cars for a living.

The idea of fitting this type of engine came about by being giving an 1800 zetec engine with cvh modified sump, type 9 box and some other goodies when i purchased a Mk1 a few weeks ago.

Im not in a hurry to do this and i'm happy to take my time in obtaining the right parts as and when.

Thanks for the good work and comments.

 

P.s love the pics its exactly what im looking for could you email some more colinrowe@excite.com

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Is anything else worth keeping from the Fiesta ? if not ill sell or swop it for a mondeo !!

 

Zetecvan 2.0

I understand about your shopping list idea and its because you have done this that i have posted here. I did mods to these cars 25 years ago and sold my last Mexico about 8 years ago (for £2500) after having it 10 years and a complete rebuild XRU345K not sure where it is now but its still taxed !!

 

I am completely new to the zetec scene.I know nothing about how to go about fitting one to these cars and a "shopping list" is exactly what im looking for, im a cheap skate and / or would like to keep the cost's down by using my mechanical electrical skills as im very lucky to have my own workshop and work on cars for a living.

The idea of fitting this type of engine came about by being giving an 1800 zetec engine with cvh modified sump, type 9 box and some other goodies when i purchased a Mk1 a few weeks ago.

Im not in a hurry to do this and i'm happy to take my time in obtaining the right parts as and when.

Thanks for the good work and comments.

 

P.s love the pics its exactly what im looking for could you email some more colinrowe@excite.com

 

If you can pickup a running 93 mondeo for peanuts you should have virtually everything you need (most importantly ecu/wiring/fusebox) and will do the job for a lot less than the £700 I spent. I made my own water rail (as I was'nt sure the retro ford/ raceline ones have the right thread for the mondeo/escort water temp/ fan control sensor) so thats another £200+ saved. I will sort out some photo's for you and my conversion parts list.

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Wow,zetec conversion on the cheap,i'll have some of that. :thumbsup:

Make own water rail :? ?

 

Planing on doin a zetec into my mk2 escy within the next year but gonna have to be cheap as poss coz i got no money,i have got a smashed up 2.0l mondeo on a v plate.

Theres a start anyway :D

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Wow,zetec conversion on the cheap,i'll have some of that. :thumbsup:

Make own water rail :? ?

 

Planing on doin a zetec into my mk2 escy within the next year but gonna have to be cheap as poss coz i got no money,i have got a smashed up 2.0l mondeo on a v plate.

Theres a start anyway :D

 

One water rail not pretty but it works.

cortina025.jpg

Does a V reg mondeo have the blacktop engine. If it does it might be a bit more challenging electrically. I think the backtop wiring uses a different plug and sensor connection set (have to look in to using the chipped locks and keys to sort the pats, this makes the ecu unique to the car). Don't throw anything away.

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Yes, the temp sensor threads are different. As Pauln says, don't throw anything away. I kept going back to my stash of parts to cobble things together.

 

Regarding stuff on the cheap, my 2 litre cost me £80 on ebay and it was only 10 miles away. They come up all the time so you could probably get one even cheaper if you bide your time.

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Can someone tell me:

 

1 what fuel pump / tank or mods do we need to do to run the Zetec.

2 what battery and where to fit.

 

I have now purchased a 105e that has the escort cross member / struts etc.

I might fit my zetec into this instead of the escort as i have bought a 1600 gt which will be a quick fit so i can run it next season.

 

Is there much differance between the 2 cars what parts might be different?

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Can someone tell me:

 

1 what fuel pump / tank or mods do we need to do to run the Zetec.

 

Are you going injection? If so, you'll need to fit high pressure fuel hoses and a return pipe back to the tank. There's a connector you can buy from kit car specialists.

 

Pump: You'll need a high pressure one for injection or a normal electric one for carbs.

 

2 what battery and where to fit.

 

Put it in the boot. I just went down to Halfords with the dimensions of the place I put it and looked for a car with a similar size engine.

 

I have now purchased a 105e that has the escort cross member / struts etc.

I might fit my zetec into this instead of the escort as i have bought a 1600 gt which will be a quick fit so i can run it next season.

 

Is there much differance between the 2 cars what parts might be different?

 

The Escort crossmember will move your engine back two inches. Great for weight distribution but you'll have to cut/move your bulkhead too.

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Might be better to fit the crossflow in the Anglia then ? What crossmember would i need to fit Zetec without cutting bulkhead :sad:

 

Keep to the Zetec plan for the Escort ?

 

I wanted to do the Escort for my missus to drive but maybe she will be using the Anglia..................... i havent even told her i've bought it yet :mrgreen: thats the beauty of having a workshop she very rarely visits, and business is a bit slow at present so maybe i could get it done quicker than i thought.

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Stick with the anglia crossmember and steering box. You would have to put a little 'pocket' in the bulkhead for the retro ford water rail. However, if you use the more expensive but nicer to look at Raceline one, you can get away with a couple of taps from a large hammer.

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(excuse my terminology here)

 

tank - what i did was to remove the outlet (large nut with pipe attached) from the bottom, cut the pipe off and drill the hole larger. Then i braised in some 8mm copper pipe as the original fuel line is 6mm but injection is 8mm.

 

fuel pump /filter - get ANY injection external pump - i used one from a sierra (Was £5 from breakers) and then bought a new fuel filter (about £3 ebay - from a focus i think?) then mounted these in a prepfab filter/pump cradle. which was bolted to the boot floor with 4 exhaust rubber cotton reel thingys.

also the inlet on the pump is 15mm so i used a 15mm-8mm copper reducer from B+Q :thumbsup:

also the outlet is a 12x1.5 thread which normally takes a banjo fitting so i got an adapter from a hose supplier which took it to an 8mm tail

 

its not pretty, but is cheap and under the car so not seen anyway

 

DSC00169.jpg

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Stick with the anglia crossmember and steering box. You would have to put a little 'pocket' in the bulkhead for the retro ford water rail. However, if you use the more expensive but nicer to look at Raceline one, you can get away with a couple of taps from a large hammer.

 

 

It already has escort crossmember and struts been fitted about 5 years ago so the steering box etc is long gone.

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Been looking at wiring the Engine up i know lots of people are using megasquirt.

 

Where's a good supplier and did you get a wiring loom etc with it, how did you wire the engine bay ?

 

I've spoke to some one today who supplies a kit including a loom.

All i will need to do is convert to the ford loom / main harness.

After a chat with him we decided it wouldn't be too hard to include a new fusebox that attaches to the ecu and make a new complete front loom for the lights, horn indicators etc based on an original and be able to connect to the main harness inside the car.

 

If i spent the time looking into and making this would anyone else be interested ? I'm thinking if you wanted to do a conversion you could just plug and play with this new loom :)

 

Am i wasting my time ? has someone already done this ?

I'm going to do something for my car but ifs there's interest then i will try to adapt my idea for a easy fit similar to the water rails and other mod parts that come "off the shelf"

 

Any thought would be appricated.

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I'm using a megasquirt. I got it from http://www.glensgarage.com/catalog/index.php

 

I've built a spare megasquirt, and it took me two evenings. I took my time, followed the guide and it worked perfectly.

 

I didn't get the engine loom with it, but when I got my engine it came with the Zetec wiring so all I needed to do was solder the correct wires into the squirt. It was easier than I thought it would be. Just took it one wire at a time.

 

A lot of people do seem to want a plug and play solution with the megasquirt though, so an off the shelf solution would be good.

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Thanks for the input ..............making looms is 2nd nature to me as i'm wiring in aftermarket products in all day, i also do work on fitting out Police vehicles etc so i feel i'm "qualified" enough to carry this out.

 

13-12-2007034.jpg

 

Here one we did earlier !!!!

 

Zetecvan did you replace all your loom or just the engine bay ?

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