FAF267.zetecconversion
Content
fasttech fast tech f re ef o b e
af t te r e r
Words and photos: ai B
Zetec InsIde Well, there soon Will be. We folloW ff snapper ade brannan’s escort estate’s sWap to Zetec poWer.
A
year ago I ound that the equipment I was taking to shoots had ar outgrown a regular hatchback and I had to fnd an estate. None o the typical modern options really took my ancy ancy,, but being a die-hard ‘80s Ford an the now very rare Mk4 Escort estate did! Ater a long search I ound this solid example and put it to work. All was great except or the standard 75bhp 1.4 which was giving around 20mpg! An RS Turbo powerplant would have been a nice easy fx, but that was never going to be economical, and I would just end up tuning it and breaking it. A sensible motorway-munching lump was needed. A turbo diesel
might be the most logical thing to ft, but I’m allergic to the weird powerband, clattery engine note and all the inevitable soot. So, a 2-litre 16-valve Mondeo engine seemed like the best compromise. More than standard RST power and torque, decent mpg and they’re cheap and plentiul. The Escort really needs to be on the road earning me a living and not being another project so a trip to SiTech Racing was in order or a quick turnaround in its capable hands. Main Main man Simon’s usually used to dealing with big power builds but at the same time is always open to a challenge and something dierent, so the estate’s conversion went to him.
EssEnt i a ials ls
What you’ll need! Costs
Engine, K&N, ECU, loom £200 Used our-br our-branch anch maniold £20 Custom stainless exhaust £200 0925 multi-groove alternator belt £5 Timing belt and tensioner kit £40 Oil, oil lter and anti-reeze £25 Spark plugs £10 Repro uel pump hanger £50 (or used £10) New pattern RS/XR uel tank including swirl pot £60 Inertia switch £5 Inline an switch and temp gauge housings £20 each Wire, connectors, relays, uses, hose clips etc £30
Where From?
Free ads, eBay, motor actors hoW long to do?
A long weekend hoW hard to Fit?
I you’ve tted a standard engine you can do this. There are some ddly areas though. in the toolkit
Engine hoist, axle stands, drill, Mig welder, spanners, screwdrivers Thanks
www.sitechracing.com www.simonscustom exhausts.co.uk
Fast Ford july Ford july 2008 0 1 0 9
fasttech / tooled Up / ZETEC CONVERSION
1
Remove air con, alternator bracket, two-piece Mondeo sump and Zetec engine mount and chuck them in the bin.
3
There’s a huge range o Zetec inlet maniolds but some like the 2-litre Mondeo version won’t t in a Mk4 Escort. We used a 1.6 Escort maniold with the 2-litre injectors and throttle body tted.
fasttech
/
2
6
While the engine is out you can t the Escort/Fiesta sump, dipstick, oil pick-up and water pump rom a 1.6/1.8 Zetec. My Mondy engine had already had this done as it had been tted to a Mk6 Escort.
The CVH engine mount needs adapting. Oer it up, and you’ll see how. One lug with a mounting hole has to be cut o and re-welded on the opposing side so it matches with the Zetec’s bolt layout.
8
4
While you’ve got the engine out it would be criminal not to t a new timing belt, tensioner and idler pulleys, available in kit orm cheaply at all motor actors.
5
We used a 220mm clutch rom a 1.8 Zetec. Also available in the same size with a crank trigger is the FRST clutch and fywheel with more uprated options, but a actory clutch is ne or our power levels.
10
I, like me, you’re using an originally carbed car the whole uel system will need uprating. The RS Turbo/XR3i system is perect.
We opted to remove the anti-roll bar and drop the old CVH engine and gearbox out below.
7
Fit the CVH alternator brackets and Zetec alternator, it’s tight but it all lines up perectly! An 0925 multi-groove belt is what you now need to purchase as no actory Ford option is quite right.
9
The original 1.4 CVH gearbox spacer plate blanks the crank trigger, so this must be trimmed to accommodate.
11
During a visit to Ford I ound that most o the RS/XR electric pump hanger set-up is no longer available. A search on eBay ound this nice custom repro hanger, ree o rust and seized bolts that used versions always have. We chose to mount the pump ully under the spare wheel well as opposed to hal on the chassis as per the actory design. This kept it urther rom the exhaust and any speed bumps. Fast Ford july 2008
0 1 1 0 july 2008 Fast Ford
fasttech / tooled Up / ZETEC CONVERSION
fasttech
/
12
0111
15
The coolant hoses t with some mixing and cutting o CVH and Zetec parts. For the temperature gauge and an switch inline universal sender housings are ideal, and handily join the hybrid hoses.
16
Sourcing the correct tank complete with swirl pot, injection outlets and sender compatibility can be tricky as there are countless minor variations. Here the sender proved to be too small. So, a circular section was cut rom the old tank (which had been drained, soaked and thoroughly fushed out), hammered fat and then slotted in under the sender’s securing seal. A top bit o SiTech resourceulness in action!
13
Feed wiring rom the pump through the grommet under the rear seat to an ignition live used relay. An inertia switch’s a good saety addition and can be ound in most modern cars in a breaker’s yard. 0 1 1 2 july 2008 Fast Ford
14
Crane the engine back in. Now that the modded engine mount is tted everything will bolt up just as i it was a actory installation.
The original engine loom has a couple o now redundant handy ignition-switched lives rom the coil and distributor that can have relays added or the new set-up.
18
The 1.4 CVH throttle cable tted straight on, with only the surround requiring some trimming or ull travel to be achieved.
17
It’s always advisable to use a wiring diagram, but as a basic guide we ound that the main connections were: Green/black – engine sensor power Red/black – Lambda power Black – ignition and injector power Brown – earth
19
This engine came with a our-branch maniold, which just tted in. It’s tight but there’s no need to use a CVH maniold (which requires retapping the head). A standard Escort/Fiesta maniold should also t. Fast Ford july 2008
0113
fasttech / tooled Up / ZETEC CONVERSION
fasttech
/
12
15
The coolant hoses t with some mixing and cutting o CVH and Zetec parts. For the temperature gauge and an switch inline universal sender housings are ideal, and handily join the hybrid hoses.
16
Sourcing the correct tank complete with swirl pot, injection outlets and sender compatibility can be tricky as there are countless minor variations. Here the sender proved to be too small. So, a circular section was cut rom the old tank (which had been drained, soaked and thoroughly fushed out), hammered fat and then slotted in under the sender’s securing seal. A top bit o SiTech resourceulness in action!
13
14
Feed wiring rom the pump through the grommet under the rear seat to an ignition live used relay. An inertia switch’s a good saety addition and can be ound in most modern cars in a breaker’s yard.
The original engine loom has a couple o now redundant handy ignition-switched lives rom the coil and distributor that can have relays added or the new set-up.
18
Crane the engine back in. Now that the modded engine mount is tted everything will bolt up just as i it was a actory installation.
The 1.4 CVH throttle cable tted straight on, with only the surround requiring some trimming or ull travel to be achieved.
fasttech / tooled
19
This engine came with a our-branch maniold, which just tted in. It’s tight but there’s no need to use a CVH maniold (which requires retapping the head). A standard Escort/Fiesta maniold should also t.
Up / ZETEC CONVERSION /
21
20
The Zetec maniold won’t mate up to a CVH exhaust. I had a stainless system made by www.simonscustomexhausts.com. The standard exhaust was welded on but this was very restrictive higher in the rev range. The 2in bore system let it breath ar easier.
Get a good condition loom with no missing connectors. I learnt the hard way with a loom that had the air temp sensor plug missing, it had been cut back just a bit
It’s always advisable to use a wiring diagram, but as a basic guide we ound that the main connections were: Green/black – engine sensor power Red/black – Lambda power Black – ignition and injector power Brown – earth
Fast Ford july 2008
0 1 1 2 july 2008 Fast Ford
Top Tip
17
The ECU isn’t waterproo, so the best thing to do is drill a hole in the bulkhead and eed through each labelled pin rom the main connector, which can then be mounted under the glovebox.
ConClusion With the 2-litre tted the car is totally transormed, and to be honest a lot quicker than I was expecting! So much so that it’s easily outgrown the standard suspension, which will have to
Escort’s original gearbox. A ve-minute blast with Zetec power destroyed one o the di bearings. All is well now though with a LSD ’box rom an S2 RST now evenly spreading the
0113
fasttech / tooled
Up / ZETEC CONVERSION /
21
20
The Zetec maniold won’t mate up to a CVH exhaust. I had a stainless system made by www.simonscustomexhausts.com. The standard exhaust was welded on but this was very restrictive higher in the rev range. The 2in bore system let it breath ar easier.
Top Tip Get a good condition loom with no missing connectors. I learnt the hard way with a loom that had the air temp sensor plug missing, it had been cut back just a bit too far making installation more time consuming. This can be especially frustrating when you find out after the engine is fitted and you are desperate to get it up and running.
0114
july 2008 Fast Ford
The ECU isn’t waterproo, so the best thing to do is drill a hole in the bulkhead and eed through each labelled pin rom the main connector, which can then be mounted under the glovebox.
ConClusion With the 2-litre tted the car is totally transormed, and to be honest a lot quicker than I was expecting! So much so that it’s easily outgrown the standard suspension, which will have to be replaced soon, as the car is more like a torque-steering bouncy castle than the relaxed cruiser I was expecting! To prove how much extra torque the 2-litre produces you only need to see the
Escort’s original gearbox. A ve-minute blast with Zetec power destroyed one o the di bearings. All is well now though with a LSD ’box rom an S2 RST now evenly spreading the power between each wheel. For ultimate power and un I’d still choose a turbo lump, but or a daily driver or even a hassle ree track car, a 2-litre Zetec on standard management is a great option.
af t te r e r
Words and photos: ai B
Zetec InsIde Well, there soon Will be. We folloW ff snapper ade brannan’s escort estate’s sWap to Zetec poWer.
A
year ago I ound that the equipment I was taking to shoots had ar outgrown a regular hatchback and I had to fnd an estate. None o the typical modern options really took my ancy ancy,, but being a die-hard ‘80s Ford an the now very rare Mk4 Escort estate did! Ater a long search I ound this solid example and put it to work. All was great except or the standard 75bhp 1.4 which was giving around 20mpg! An RS Turbo powerplant would have been a nice easy fx, but that was never going to be economical, and I would just end up tuning it and breaking it. A sensible motorway-munching lump was needed. A turbo diesel
might be the most logical thing to ft, but I’m allergic to the weird powerband, clattery engine note and all the inevitable soot. So, a 2-litre 16-valve Mondeo engine seemed like the best compromise. More than standard RST power and torque, decent mpg and they’re cheap and plentiul. The Escort really needs to be on the road earning me a living and not being another project so a trip to SiTech Racing was in order or a quick turnaround in its capable hands. Main Main man Simon’s usually used to dealing with big power builds but at the same time is always open to a challenge and something dierent, so the estate’s conversion went to him.
EssEnt i a ials ls
What you’ll need! Costs
Engine, K&N, ECU, loom £200 Used our-br our-branch anch maniold £20 Custom stainless exhaust £200 0925 multi-groove alternator belt £5 Timing belt and tensioner kit £40 Oil, oil lter and anti-reeze £25 Spark plugs £10 Repro uel pump hanger £50 (or used £10) New pattern RS/XR uel tank including swirl pot £60 Inertia switch £5 Inline an switch and temp gauge housings £20 each Wire, connectors, relays, uses, hose clips etc £30
Where From?
Free ads, eBay, motor actors hoW long to do?
A long weekend hoW hard to Fit?
I you’ve tted a standard engine you can do this. There are some ddly areas though. in the toolkit
Engine hoist, axle stands, drill, Mig welder, spanners, screwdrivers Thanks
www.sitechracing.com www.simonscustom exhausts.co.uk
Fast Ford july Ford july 2008 0 1 0 9
fasttech / tooled Up / ZETEC CONVERSION
1
Remove air con, alternator bracket, two-piece Mondeo sump and Zetec engine mount and chuck them in the bin.
3
There’s a huge range o Zetec inlet maniolds but some like the 2-litre Mondeo version won’t t in a Mk4 Escort. We used a 1.6 Escort maniold with the 2-litre injectors and throttle body tted.
fasttech
/
2
6
While the engine is out you can t the Escort/Fiesta sump, dipstick, oil pick-up and water pump rom a 1.6/1.8 Zetec. My Mondy engine had already had this done as it had been tted to a Mk6 Escort.
The CVH engine mount needs adapting. Oer it up, and you’ll see how. One lug with a mounting hole has to be cut o and re-welded on the opposing side so it matches with the Zetec’s bolt layout.
8
4
While you’ve got the engine out it would be criminal not to t a new timing belt, tensioner and idler pulleys, available in kit orm cheaply at all motor actors.
5
We used a 220mm clutch rom a 1.8 Zetec. Also available in the same size with a crank trigger is the FRST clutch and fywheel with more uprated options, but a actory clutch is ne or our power levels.
10
I, like me, you’re using an originally carbed car the whole uel system will need uprating. The RS Turbo/XR3i system is perect.
We opted to remove the anti-roll bar and drop the old CVH engine and gearbox out below.
7
Fit the CVH alternator brackets and Zetec alternator, it’s tight but it all lines up perectly! An 0925 multi-groove belt is what you now need to purchase as no actory Ford option is quite right.
9
The original 1.4 CVH gearbox spacer plate blanks the crank trigger, so this must be trimmed to accommodate.
11
During a visit to Ford I ound that most o the RS/XR electric pump hanger set-up is no longer available. A search on eBay ound this nice custom repro hanger, ree o rust and seized bolts that used versions always have. We chose to mount the pump ully under the spare wheel well as opposed to hal on the chassis as per the actory design. This kept it urther rom the exhaust and any speed bumps. Fast Ford july 2008
0 1 1 0 july 2008 Fast Ford
fasttech / tooled Up / ZETEC CONVERSION
fasttech
/
12
0111
15
The coolant hoses t with some mixing and cutting o CVH and Zetec parts. For the temperature gauge and an switch inline universal sender housings are ideal, and handily join the hybrid hoses.
16
Sourcing the correct tank complete with swirl pot, injection outlets and sender compatibility can be tricky as there are countless minor variations. Here the sender proved to be too small. So, a circular section was cut rom the old tank (which had been drained, soaked and thoroughly fushed out), hammered fat and then slotted in under the sender’s securing seal. A top bit o SiTech resourceulness in action!
13
Feed wiring rom the pump through the grommet under the rear seat to an ignition live used relay. An inertia switch’s a good saety addition and can be ound in most modern cars in a breaker’s yard. 0 1 1 2 july 2008 Fast Ford
14
Crane the engine back in. Now that the modded engine mount is tted everything will bolt up just as i it was a actory installation.
The original engine loom has a couple o now redundant handy ignition-switched lives rom the coil and distributor that can have relays added or the new set-up.
18
The 1.4 CVH throttle cable tted straight on, with only the surround requiring some trimming or ull travel to be achieved.
17
It’s always advisable to use a wiring diagram, but as a basic guide we ound that the main connections were: Green/black – engine sensor power Red/black – Lambda power Black – ignition and injector power Brown – earth
19
This engine came with a our-branch maniold, which just tted in. It’s tight but there’s no need to use a CVH maniold (which requires retapping the head). A standard Escort/Fiesta maniold should also t. Fast Ford july 2008
0113
fasttech / tooled Up / ZETEC CONVERSION
fasttech
/
12
15
The coolant hoses t with some mixing and cutting o CVH and Zetec parts. For the temperature gauge and an switch inline universal sender housings are ideal, and handily join the hybrid hoses.
16
Sourcing the correct tank complete with swirl pot, injection outlets and sender compatibility can be tricky as there are countless minor variations. Here the sender proved to be too small. So, a circular section was cut rom the old tank (which had been drained, soaked and thoroughly fushed out), hammered fat and then slotted in under the sender’s securing seal. A top bit o SiTech resourceulness in action!
13
14
Feed wiring rom the pump through the grommet under the rear seat to an ignition live used relay. An inertia switch’s a good saety addition and can be ound in most modern cars in a breaker’s yard.
The original engine loom has a couple o now redundant handy ignition-switched lives rom the coil and distributor that can have relays added or the new set-up.
18
Crane the engine back in. Now that the modded engine mount is tted everything will bolt up just as i it was a actory installation.
The 1.4 CVH throttle cable tted straight on, with only the surround requiring some trimming or ull travel to be achieved.
fasttech / tooled
19
This engine came with a our-branch maniold, which just tted in. It’s tight but there’s no need to use a CVH maniold (which requires retapping the head). A standard Escort/Fiesta maniold should also t.
Up / ZETEC CONVERSION /
21
20
The Zetec maniold won’t mate up to a CVH exhaust. I had a stainless system made by www.simonscustomexhausts.com. The standard exhaust was welded on but this was very restrictive higher in the rev range. The 2in bore system let it breath ar easier.
Get a good condition loom with no missing connectors. I learnt the hard way with a loom that had the air temp sensor plug missing, it had been cut back just a bit
It’s always advisable to use a wiring diagram, but as a basic guide we ound that the main connections were: Green/black – engine sensor power Red/black – Lambda power Black – ignition and injector power Brown – earth
Fast Ford july 2008
0 1 1 2 july 2008 Fast Ford
Top Tip
17
The ECU isn’t waterproo, so the best thing to do is drill a hole in the bulkhead and eed through each labelled pin rom the main connector, which can then be mounted under the glovebox.
ConClusion With the 2-litre tted the car is totally transormed, and to be honest a lot quicker than I was expecting! So much so that it’s easily outgrown the standard suspension, which will have to
Escort’s original gearbox. A ve-minute blast with Zetec power destroyed one o the di bearings. All is well now though with a LSD ’box rom an S2 RST now evenly spreading the
0113
fasttech / tooled
Up / ZETEC CONVERSION /
21
20
The Zetec maniold won’t mate up to a CVH exhaust. I had a stainless system made by www.simonscustomexhausts.com. The standard exhaust was welded on but this was very restrictive higher in the rev range. The 2in bore system let it breath ar easier.
Top Tip Get a good condition loom with no missing connectors. I learnt the hard way with a loom that had the air temp sensor plug missing, it had been cut back just a bit too far making installation more time consuming. This can be especially frustrating when you find out after the engine is fitted and you are desperate to get it up and running.
0114
july 2008 Fast Ford
The ECU isn’t waterproo, so the best thing to do is drill a hole in the bulkhead and eed through each labelled pin rom the main connector, which can then be mounted under the glovebox.
ConClusion With the 2-litre tted the car is totally transormed, and to be honest a lot quicker than I was expecting! So much so that it’s easily outgrown the standard suspension, which will have to be replaced soon, as the car is more like a torque-steering bouncy castle than the relaxed cruiser I was expecting! To prove how much extra torque the 2-litre produces you only need to see the
Escort’s original gearbox. A ve-minute blast with Zetec power destroyed one o the di bearings. All is well now though with a LSD ’box rom an S2 RST now evenly spreading the power between each wheel. For ultimate power and un I’d still choose a turbo lump, but or a daily driver or even a hassle ree track car, a 2-litre Zetec on standard management is a great option.
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