2.0l Zetec Conversion

eskyvator · 02-02-2010, 03:19 PM

Hi all!,

I'm currently doing some homework on a 2.0L Zetec conversion and would like you all to throw your 2c in.

I am hoping Graham Flood will join me on the project but he needs me to find out a few things

- Wiring Loom: I still have the original, but will this do the job? Who can I call in the sydney area to ask some questions?

- Bellhousing: I spoke to Jeff at Dellows and he custom makes a bellhousing for the w series gearbox, oh yeah! Answered my own question.

- Converting: Burton can supply all the things necessary for this conversion and as Graham has never done this conversion before would it be wise to get them to supply the parts i need to do this conversion?

Let me know if you have had this conversion done becaus any light you can shine would be of great help to me, my back pocket and my mechanics brain!

A pic of my girl

Puzzlescort · 02-02-2010, 04:15 PM

try here

http://classicford.mine.nu/forum/forum.asp?FORUM_ID=8

plenty of examples, even check out the project section

JC807 · 02-02-2010, 04:33 PM

from what i've read Dellows don't make the best bellhousings...

eskyvator · 02-02-2010, 05:09 PM

Spoke to a very friendly bloke by the name of jeff today, they do now. $550 a pop.

eskyvator · 02-02-2010, 07:29 PM

Does anyone know where I can get a wiring harness from a 2004 focus, and maybe the diagrams?

Dellows are the only ones (that I know of) that make the one I need. If you know anyone who makes a better bellhousing for a w series toyota gearbox for use on a focus engine please let me know.

V8falcons · 02-02-2010, 07:37 PM

[QUOTE=eskyvator]Hi all!,

I'm currently doing some homework on a 2.0L Zetec conversion and would like you all to throw your 2c in.

I am hoping Graham Flood will join me on the project but he needs me to find out a few things

- Wiring Loom: I still have the original, but will this do the job? Who can I call in the sydney area to ask some questions?

- Bellhousing: I spoke to Jeff at Dellows and he custom makes a bellhousing for the w series gearbox, oh yeah! Answered my own question.

- Converting: Burton can supply all the things necessary for this conversion and as Graham has never done this conversion before would it be wise to get them to supply the parts i need to do this conversion?

Let me know if you have had this conversion done becaus any light you can shine would be of great help to me, my back pocket and my mechanics brain!
[QUOTE=eskyvator]

gday mate this conversion is almost an off the shelf job now in the uk,its a good engine for the escort and can be had extremely cheap(my 2ltr zetec was $50 on ebay)get your self a classic ford mag and a have a read as almost every second mk2 has one in them now,as for the box you know the escort 4 speed or sierra 5 speed bolts directly to the zetec block!!!!!!!!!!

Ok I had/researched most of this gear for my RS but changed plans(sold it all off), you will need a rwd water rail ,raceline,burtons or even jeff at eurospeed in QLD can sort you for that,or keep an eye out on ebay, rwd extractors or use the fwd manifold and make up a new down pipe if your on a budget ,modified pinto flywheel or 1800 zetec job, space back the starter motor about 5mm, a bitsa clutch from zetec and escort,engine mounts can be bought off the shelf or made, just get a mondeo engine harness and use a megajolt kit using the edis module and factory sensors,as for fueling you can squezze the factory injection next to the master cyl extension or throw it away and use a st170 manifold and bike carbs or throttle bodies on a stock engine you will have around 150+ hp with this set up,then add some cams for fun.

Do a little home work and you will save your self some money not using places like dellows for all your conversion parts.
see the link listed bellow
good luck with the conversion

eskyvator · 03-02-2010, 11:18 AM

Quote:

just get a mondeo engine harness and use a megajolt kit using the edis module and factory sensors

By engine harness do you mean the wiring? because I am trying to track that down at the moment.

Quote:

for fueling you can squezze the factory injection next to the master cyl extension or throw it away and use a st170 manifold and bike carbs or throttle bodies on a stock engine

What's a st170 manifold? where would I get one?

Thanks for your help mate.

I was wondering anyone knew of somebody in aus that has had this conversion done to a mk2?

Fev · 03-02-2010, 11:42 AM

For all your Zetec MKII needs see

http://www.zetecescorts.bravehost.com/

Fev · 03-02-2010, 04:31 PM

A better though more expensive choice would be a 2L Duratec engine like what the Fiesta XR4's run. The engine makes more power and also weighs about 20kg LIGHTER then the Zetec. It's not as common a conversion though but it will net much better gains

outback_ute · 03-02-2010, 05:53 PM

Fev, is the difference as simple as the Duratec having an alloy block instead of Zetec cast iron?

Quote:

Originally Posted by vctxr6ute

or throw it away and use a st170 manifold and bike carbs or throttle bodies on a stock engine you will have around 150+ hp with this set up,then add some cams for fun.

Beware most states require a transplanted engine to meet the emissions regs from the year of the engine.

V8falcons · 03-02-2010, 07:30 PM

Quote:

Originally Posted by outback_ute

Fev, is the difference as simple as the Duratec having an alloy block instead of Zetec cast iron?

Beware most states require a transplanted engine to meet the emissions regs from the year of the engine.

ah I was under the impression it was the year the car was manufactured.

The blocks are different and nothing is interchangable between the 2 engines,if you were going for a duratec the 2.3ltr sp23 mill would be the pick.

V8falcons · 03-02-2010, 07:39 PM

Quote:

Originally Posted by eskyvator

By engine harness do you mean the wiring? because I am trying to track that down at the moment.

What's a st170 manifold? where would I get one?

Thanks for your help mate.

I was wondering anyone knew of somebody in aus that has had this conversion done to a mk2?

go to the classic ford link down the page abit and have a read of the engine conversion section. there is a red RS2000 in melbourne and few around sydney and look in http://www.turbosport.co.uk/forum.php.

yes the engine harness is the engine wiring,most good wreckers will have a mondeo harness or 7 laying around. theres a few at picknpayless at blacktown. what computor are you going to run???? you may need the EDIS module as well.
The st170 manifold is off a 2002ish focus st170 and is an easy way to run throttle bodies,or bike carbs using the factory fuel rail and injections if you like. you can buy them new from ford,they are around $220 last I checked
Have a read on the internet there is plenty of info around before you hand over your cash to anyone!

whooligan · 03-02-2010, 08:52 PM

Quote:

Originally Posted by Fev

A better though more expensive choice would be a 2L Duratec engine like what the Fiesta XR4's run. The engine makes more power and also weighs about 20kg LIGHTER then the Zetec. It's not as common a conversion though but it will net much better gains

I'll give you the tip right now....My soon to be sold Zetec Escort is quicker than my XR4 Fiesta and a lot more fun to drive. Bang for your buck, zetec is still the way to go. Conversion parts are ludicurously expensive for the duratec and within 5 years will be obselete, anyway. Ford are talking about fitting a turbo charged 4cyl in a RWD Falcon which will have more power and should be a pretty straight forward conversion being North/South configuration.

Also don't let emissons scare you. Its utter crap about meeting the year level of the donor motor. According to the engineers who inspected my car it just has to be better/less polluting than the original engine. The EPA has some clout apparently, but I've yet to hear of anyone having their car taken off the road for having a cleaner engine fitted.

Its well worth speaking to an engineer about doing a zetec conversion. Mine charged me a couple of hundred bucks, and he said he liked these types of conversions as long as you don't go overboard with the tune/turbo kits/monster wheels/exhausts etc.....all that stuff can be done later if you feel you need to.

Its a great conversion....pity I have to sell mine.

:

outback_ute · 04-02-2010, 11:48 AM

vctxr6ute I realise they completely different engines, I was just trying to account for the weight difference.

I think the emissions regs is a thing that varies by state, haven't fully researched it myself (but ought to start, to work out what to do with my Esky)

eskyvator · 05-02-2010, 12:23 PM

Quote:

look in http://www.turbosport.co.uk/forum.php.
For all your Zetec MKII needs see
http://www.zetecescorts.bravehost.com/
03-02-10 11:18 AM

Great sites thanks for the links, really comprhensive.

Whooligan, you're are no fuss, straight talking bloke! Thanks for the advice.

Been a bit distarcted this week so I havn't been able to track anything other than
- Gearbox (w55 supra)
- Bellhousing (dellows)

Next week I need to sort out a clutch, harness, st170 manifold, throttle bodies etc. It's a long list but i'm way keen!

Hydraulic or cable clutch?

It's friday so it's scotch and dry time lads, Have a good weekend!

Zetec_RS · 11-02-2010, 11:14 PM

You can also go for the Steel case Celica box (W50) as I think it's a little narrower than the W55 - you will need all the room you can spare as it's a tight fit (with a little hammering!). With the correct length extension housing the shifter will pop up through the original hole

:

Original cable clutch is fine although you may need to engage a clutch specialist to help set up the geometry. There is a missmatch in the clutch fork and the required travel for the Ford clutch on the Toyota box which will see you wear out friction plates due to lack of correct adjustment. You will also need a Ford / Toyota hybrid clutch assy.

You may also need to remove the brake booster etc depending on your choice of induction. I'm required by the local authorities to retain the OEM intake, ECU for the Zetec hence the OEM manifold fitted below. It's actually the later black top (Focus) unit as the Mondeo is a lot wider and comes close to fouling on the strut tower. I will be running a bias pedal box and uprated discs all round.

If money is no object everything is an "off the shelf" item from the UK. I will be manufacturing most of the items (mounts, sump) but I have purchased some items due to appearance (Raceline water rail) and unrivalled quality for the money (105speed headers).

I'm about to fab the engine mounts now.........then onto the sump!

outback_ute · 15-02-2010, 01:57 PM

Looks great

Zetec_RS · 27-07-2010, 10:47 PM

A small update - just sorting out inlet etc as I need to run an enclosed airbox donated from a Nissan Maxima

Linking the OEM Focus inlet manifold to the airbox with a custom alloy inlet pipe and the OEM Mondeo AFM and pipe.

DOG20L · 29-07-2010, 08:40 AM

Those all look great guys. Is there a general consensus on what NA 4cyl gives the best power. Not just thinking of Ford stuff here. The kit car makers seem to like the Honda stuff but I believe they spin the wrong way.
How do the Zetecs compare with the old Twin Cam Coswoths>

Rev28K · 03-08-2010, 10:04 PM

I'd check this but as I understand it the "old" Honda engines spun the wrong way. The new ones like the K series don't (they were getting in to product sharing with other manufacturers). I also heard a rumour about a rare Toyota diff bit that would reverse the direction if you used it with an old Honda engine and a normal inline gearbox.

Dont Caterham (as well as Dare, Ginetta, etc) use Zetec's now? Partly because of European emmissions compliance?

Escort Jes · 11-02-2011, 08:38 PM

Quote:

Originally Posted by Zetec_RS

You can also go for the Steel case Celica box (W50) as I think it's a little narrower than the W55 - you will need all the room you can spare as it's a tight fit (with a little hammering!). With the correct length extension housing the shifter will pop up through the original hole

:

Original cable clutch is fine although you may need to engage a clutch specialist to help set up the geometry. There is a missmatch in the clutch fork and the required travel for the Ford clutch on the Toyota box which will see you wear out friction plates due to lack of correct adjustment. You will also need a Ford / Toyota hybrid clutch assy.

You may also need to remove the brake booster etc depending on your choice of induction. I'm required by the local authorities to retain the OEM intake, ECU for the Zetec hence the OEM manifold fitted below. It's actually the later black top (Focus) unit as the Mondeo is a lot wider and comes close to fouling on the strut tower. I will be running a bias pedal box and uprated discs all round.

If money is no object everything is an "off the shelf" item from the UK. I will be manufacturing most of the items (mounts, sump) but I have purchased some items due to appearance (Raceline water rail) and unrivalled quality for the money (105speed headers).

I'm about to fab the engine mounts now.........then onto the sump!

Hi, interested in your build, doin a mk1 with a zetec myself. did you buy headers in aus or import from uk?

Zetec_RS · 19-02-2011, 12:57 AM

Hi

Headers came from 105speed in the UK http://www.105speed.com/

Speak to Neil - he also frequents Turbosport and sells a lot of his gear through this forum http://www.turbosport.co.uk/

Highly recommended!

As I may have said above, many of the components can be fabricated relatively easily using similar principles already used on the Escort. I'm only buying items where I feel the purchaced item is far superior to someting I would make (Raceline water rail etc).

Currently sorting out the rust in my shell in an effort to get it painted this year - here is the thread rather than duplicating http://classicford.mine.nu/forum/top...?TOPIC_ID=9134

filoil · 24-02-2011, 07:04 AM

just a pic to keep you motovited (hope it loads up). ST 170 inlet manifold, Honda fireblade throttle bodies, Ashley exhaust, Raceline water rail, Focus 1.8 waterpump (for correct rotation).

whooligan · 27-02-2011, 02:55 PM

Quote:

Originally Posted by filoil

just a pic to keep you motovited (hope it loads up). ST 170 inlet manifold, Honda fireblade throttle bodies, Ashley exhaust, Raceline water rail, Focus 1.8 waterpump (for correct rotation).

What manifold did you use for the thottle bodies? I want to upgrade my basic intake and single throttle body. Is it specific for the ST170 head or is it ok for a std silvertop head?

Zetec_RS · 27-02-2011, 09:44 PM

ST170 inlet should fit the standard Blacktop or Silvertop head. You only need the flange plate which has 4 "stubs" which the individual throttle bodies can be attached with silicon hose etc.

Hope this helps.

lotuselanman · 23-07-2011, 10:42 AM

Hi,
www.retro-ford.co.uk - they have ALL the good gear for Zetec to small Fords.

Steve at : SMCKA@smckaperformance.com.au - who is great to deal with and is brining in items from Retro. He is in Sydney.
Les.

lotuselanman · 23-07-2011, 11:17 AM

Gidday,
Put my two bob's worth in and it did not show, got lost somewhere.
I am bias, I think the Zetec is the right way to go.
Same physical size as the old Ford TC, modern technoliogy and strong.
The weak point is the rod bolts, change them to ARP and you are safe for 7G all day.
Which is the better of the two ? That's up to you, phyically the are the same.
I fitted a Silvertop to a MK2 Corty with minimal X- member alterations but for all the other small Fords you need to look to Retro for parts. A good site well worth checking out, infact it is the best.
I made many items for my first engine, Steel flywheel copied from a TC unit and very light, Kent ring gear and a Gemini starter. A small dia Pressure plate ( Fiesta based from memory) and a ceramic plate from Race Clutches in Brisbane.
Made the water Rail in Stainless Steel, Aluminium is fine.
Use a Megajolt EMS for Carbs, Megasquirt for Injection, ex USA and half the price of local items.
As far as the gearbox is concernd, if you are hard on a G,box go the Toyo route. I have a 158HP Lotus Cortina and used it in competion for 10 years or more with no problems, same with the 'English" type diff.
If you want a W50 Steel case box with a short shift i have one, good for 250HP. Dellows do a bell housing to suit.
I am fitting a Silver top to my Lotus Elan which should show close 200HP and am using a T9.
I reccomend you have a good look at the Retro site as they have all the gear includinbg two stage fitting kits.
Also keep in contact with Steve at SMCKA, he is a good helpful lad.
Retro are soon to release a replica BDA type cam cover to fit direct to the Zetec.
Be careful buying extractors, keep away from Stainlees Steel as they crack,
Mild Steel is fine for us. Another trap for non Escort people is the Poms are always swapping to Rack and Pinion for all the small Ford, be aware as they R/R type will not fit with the Steering box setup.
Have fun,
Les.