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Thread: 1.6 Zetec SE engine

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by Moggy View Post
    Great news! hope you get better customer service than I did from PACE (very poor!)

    How much was it out of interest and is it 2 stage or 3 stage?
    Shawspeed posted on ZSOC Forum that he can sell one at 715£ + vat and promised an 10% discount on these. Its an 3 stage pump kit.

    I'm hoping for the delivery schedule to be faster than yours was with Pace.

    Suddenly things are looking up again. I'm thinking of going with Accralite pistons if their quote would be reasonable.
    Havent heard back from Pumabuild and their Ross racing pistons.
    Last edited by Roadsport; 23-02-2009 at 17:27.

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    Re: 1.6 Zetec SE engine

    There doesn't seem to be a lot of info on the SE engine so I would like to pick anyones brains ...

    The plan is Zetec SE into Anglia and having sourced an early phase 1 silvertop engine I have a few questions.

    1. Difference between the phase 1 and phase 2 engines
    2. Ability to recon the bottom end - I have seen info on the web that you cannot buy oversize bearings or replace the mains?
    3. Sump for RWD - Is it a case of DIY or are there modified sumps available - Don't want dry sump and am aware of Shawspeed.

    Any info greatfully received ....

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by RamJam View Post
    There doesn't seem to be a lot of info on the SE engine so I would like to pick anyones brains ...

    The plan is Zetec SE into Anglia and having sourced an early phase 1 silvertop engine I have a few questions.

    1. Difference between the phase 1 and phase 2 engines
    Phas 1 beeing with slightly inferior bottom end.The cranck float bearing having a habbit to wear out. Thats the main reason why pahase two is considered better/stronger engine. According to my experiences I'd prefer phase 2 engine prior to 04/2005 do to the 8 counterweight crank

    2. Ability to recon the bottom end - I have seen info on the web that you cannot buy oversize bearings or replace the mains?
    Haven't heard or seen o/s bearings. But yes you can replace the mains. You just need to tight and loosen the crank girdle in a certain order. Like the cylinder head.

    3. Sump for RWD - Is it a case of DIY or are there modified sumps available - Don't want dry sump and am aware of Shawspeed.
    No sump for RWD installation available. Bell housings are available. In an Anglia it could be tricky to clear the cross member.


    Any info greatfully received ....

    I'm fitting mine in Escort. Ordered the dry sump today. I still need the bellhousing to start fitting the shortblock to the engine bay.
    Last edited by Roadsport; 26-02-2009 at 17:38.

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    Re: 1.6 Zetec SE engine

    Hi guys need your expertise. I'm have a focus Mk1 1.6 zetec 1.6 se 5speed. Want to increase the power by installating a turbo charge with a low psi type. Do i need to change the piston and con rod. Can the stock piston take the boost? Thanks and appreciated.

  5. #125
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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by marchie View Post
    Hi guys need your expertise. I'm have a focus Mk1 1.6 zetec 1.6 se 5speed. Want to increase the power by installating a turbo charge with a low psi type. Do i need to change the piston and con rod. Can the stock piston take the boost? Thanks and appreciated.
    No if you run a really low boost. But then again what's the use of turbochargin if u cant use any boost or have reasonable gains.

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by RamJam View Post
    There doesn't seem to be a lot of info on the SE engine so I would like to pick anyones brains ...

    The plan is Zetec SE into Anglia and having sourced an early phase 1 silvertop engine I have a few questions.

    1. Difference between the phase 1 and phase 2 engines
    2. Ability to recon the bottom end - I have seen info on the web that you cannot buy oversize bearings or replace the mains?
    3. Sump for RWD - Is it a case of DIY or are there modified sumps available - Don't want dry sump and am aware of Shawspeed.

    Any info greatfully received ....
    Maybe the caterham wet sump would be shallow enough to clear cros member.

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by Roadsport View Post
    No if you run a really low boost. But then again what's the use of turbochargin if u cant use any boost or have reasonable gains.
    The focus is quite sluggish under power. Was thinking get a low boost just to make it more driveable. Getting a low boost cause if i were to boost it i have to change the piston and i cannot get it in my country singapore. What about 0.5bar do i need to change any parts? Thanks

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by marchie View Post
    The focus is quite sluggish under power. Was thinking get a low boost just to make it more driveable. Getting a low boost cause if i were to boost it i have to change the piston and i cannot get it in my country singapore. What about 0.5bar do i need to change any parts? Thanks
    I really don't know. 0,5 Bar could be too much since SE is a high compression ratio engine. SE is not so turbo friendly.

    Some say NOS is the easiest way to get more power.

    I'd go naturally aspirated.

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    Re: 1.6 Zetec SE engine

    Not much happening with SE's ?

    My project is moving along after a while. I've order the Alloy 7,25" clutch, flywheel,RWD water outlet and bell housing. All from BPJ services. Paul is a good man and knows he's stuff. Great service.

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by Roadsport View Post
    Not much happening with SE's ?
    Well ours is on the rolling Road Monday so should have a bit of an update after that.

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by Moggy View Post
    Well ours is on the rolling Road Monday so should have a bit of an update after that.
    Did you make it Back in one piece?

    Whats the magic number then ?

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    Re: 1.6 Zetec SE engine

    Posted some pictures to duratec installations section for Sigma rockercover modified to take direct ignition coils.

    http://www.turbosport.co.uk/showthread.php?t=141959
    Last edited by Roadsport; 01-04-2009 at 18:38.

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    Re: 1.6 Zetec SE engine

    Fitted the Dry sump kit. Everything fits neatly in place. Now clears the escort cross member nicely.


    Click image for larger version Name:	kuva 094.jpg Views:	32 Size:	1.14 MB ID:	31670

    Click image for larger version Name:	kuva 084.jpg Views:	22 Size:	1.07 MB ID:	31671

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by Moggy View Post
    Well ours is on the rolling Road Monday so should have a bit of an update after that.

    How did it go?

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    Re: 1.6 Zetec SE engine

    I'm having some fly wheel trouble. Ordered one from BPJ services but Paul is away untill 1.june. Has anyone got a clue where Paul has hes Flywheel machined? So I could contact the shop directly?

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    Re: 1.6 Zetec SE engine

    so what do i need to throttle body my mk5 zetec se engine? list if possible lol its all confussing to me but i really wana do it. Ta

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by Roadsport View Post
    I'm having some fly wheel trouble. Ordered one from BPJ services but Paul is away untill 1.june. Has anyone got a clue where Paul has hes Flywheel machined? So I could contact the shop directly?
    Now sorted. Decided to go with the flywheel I was sent.

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by e12 jrm View Post
    so what do i need to throttle body my mk5 zetec se engine? list if possible lol its all confussing to me but i really wana do it. Ta
    Throttle bodies of course.
    Injectors
    Air filter
    Trumpets
    Linkage kit
    HD valve springs would be good
    New aftermarket ECU ( ofter hear Omex beeing used)

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    Re: 1.6 Zetec SE engine

    hd big end bolts are recommended also if upping the RPM with cams

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by Roadsport View Post
    Not much happening with SE's ?

    My project is moving along after a while. I've order the Alloy 7,25" clutch, flywheel,RWD water outlet and bell housing. All from BPJ services. Paul is a good man and knows he's stuff. Great service.
    yip ,,Paul's a top guy he's been a great souce of info for me ,,I'm in the middle of doing a 1.4 Se conversion in my ex-challenge spec KA. My pistons are with him just now getting some pockets in them,,just waiting for him to come back from holiday so I can get them back. I'm planning to fit a 1.6 head some gsx 600r TBs with DTA management and a puma 1.7 sump . Been having problems with sus'n out valves and retainers ,I'm wanting to use the shim under followers which allows the use of higher lift cams . The 1.7 inlet valves are the same size as the 1.6 (30mm) but the exhaust valves are bigger on the 1.7 (26mm compared with 24mm in the 1.4/1.6 ) The shim under valves are slightly shorter and 1 valve has triple collet grooves and the other is single ! STRESS !! Also trying to find a decent exhaust manifold for as well . Does anyone know of anyone else who's fitted an SE to a Ka ? -I'd like to see pic's of the o/s engine mount. Any info would be great

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    Re: 1.6 Zetec SE engine

    theres one at ZSOC forum called Wide Ka. He had one I'm sure he can help you.

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by mikey p View Post
    hd big end bolts are recommended also if upping the RPM with cams
    true.

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by Roadsport View Post
    Throttle bodies of course.
    Injectors
    Air filter
    Trumpets
    Linkage kit
    HD valve springs would be good
    New aftermarket ECU ( ofter hear Omex beeing used)
    Fuel pressure reg too.

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by Garry.m View Post
    yip ,,Paul's a top guy he's been a great souce of info for me ,,I'm in the middle of doing a 1.4 Se conversion in my ex-challenge spec KA. My pistons are with him just now getting some pockets in them,,just waiting for him to come back from holiday so I can get them back. I'm planning to fit a 1.6 head some gsx 600r TBs with DTA management and a puma 1.7 sump . Been having problems with sus'n out valves and retainers ,I'm wanting to use the shim under followers which allows the use of higher lift cams . The 1.7 inlet valves are the same size as the 1.6 (30mm) but the exhaust valves are bigger on the 1.7 (26mm compared with 24mm in the 1.4/1.6 ) The shim under valves are slightly shorter and 1 valve has triple collet grooves and the other is single ! STRESS !! Also trying to find a decent exhaust manifold for as well . Does anyone know of anyone else who's fitted an SE to a Ka ? -I'd like to see pic's of the o/s engine mount. Any info would be great
    Best I can find:




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    Re: 1.6 Zetec SE engine

    cheers for that
    its a pitty everythings painted black . I've just spotted that he's moved the pas pump up to where the alternator used to be . Whats the score with 2 and 3 wire alternators ?
    Only a week til Paul at BPJ is back

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    Re: 1.6 Zetec SE engine

    Not sure with the alternator - Fiesta uses 2 wire. That engine is in a kit car now - using the same loom/alternator which I assume is a 2 wire. 3rd wire I think will probably be something to do with ecu control which I imagine is used on latest Focus/Fiesta.

    Alternator and PAS was swapped around because the inlet manifold fouled the alternator.

    BPJ sell inlet manifolds that miss the alternator but it's not a nice looking part - much better off with a set of Jenvey direct to heads.

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by OldDan View Post
    Not sure with the alternator - Fiesta uses 2 wire. That engine is in a kit car now - using the same loom/alternator which I assume is a 2 wire. 3rd wire I think will probably be something to do with ecu control which I imagine is used on latest Focus/Fiesta.

    Alternator and PAS was swapped around because the inlet manifold fouled the alternator.

    BPJ sell inlet manifolds that miss the alternator but it's not a nice looking part - much better off with a set of Jenvey direct to heads.

    Jenveys look nice as shown on page one in the second picture.

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    Re: 1.6 Zetec SE engine

    We swapped a carb'd Zetec-SE over to Jenvey DTHs recently. It made 186bhp on carbs, 198bhp on the bodies.

    Torque was slightly lower, but still a decent increase. Roll on mapping mine!

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    Re: 1.6 Zetec SE engine

    When I was planning my induction I tought I'd do a DCOE manifold and a pair of roller body throttle bodies.

    Went with the DTH Jenvey's because they give a more direct inlet line as the DCOE flange is longer than the Zetec SE head. And the roller barrel flow is only better with wide open throttle. Anything under WOT and the rollers flow less than the conventional butterfly bodies. And the Jenveys do not need manifold so one less seam to disturb the air flow.

    I've been wondering why the they're 42 mm in diameter. How did they end up with that diameter?

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by OldDan View Post
    Not sure with the alternator - Fiesta uses 2 wire. That engine is in a kit car now - using the same loom/alternator which I assume is a 2 wire. 3rd wire I think will probably be something to do with ecu control which I imagine is used on latest Focus/Fiesta.

    Alternator and PAS was swapped around because the inlet manifold fouled the alternator.

    BPJ sell inlet manifolds that miss the alternator but it's not a nice looking part - much better off with a set of Jenvey direct to heads.
    The DTH bodies don't fit under the Ka bonnet !...I'd have to cut a big hole in the bonnet !

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by Roadsport View Post
    When I was planning my induction I tought I'd do a DCOE manifold and a pair of roller body throttle bodies.

    Went with the DTH Jenvey's because they give a more direct inlet line as the DCOE flange is longer than the Zetec SE head. And the roller barrel flow is only better with wide open throttle. Anything under WOT and the rollers flow less than the conventional butterfly bodies. And the Jenveys do not need manifold so one less seam to disturb the air flow.

    I've been wondering why the they're 42 mm in diameter. How did they end up with that diameter?
    Not sure! There are some special made 40s in stock at shawspeed though.

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by OldDan View Post
    Not sure! There are some special made 40s in stock at shawspeed though.
    I'm surprised that there's no dth 45's.It Could be that the 42's gives wider power band than the 45's. Do to the higher flow velocity as the 45's would giwe better peak power.

    Most hi-po 4Ages run on 45's.

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    Re: 1.6 Zetec SE engine

    Visited my carage today with a camera too shoot some engine bits while they're still nice and shiny.

    FINALLY got the pistons and rods. And to them to fit with eachother.
    Click image for larger version Name:	Setecin kuvia 001.jpg Views:	17 Size:	1.41 MB ID:	34300
    Click image for larger version Name:	Setecin kuvia 005.jpg Views:	4 Size:	1.41 MB ID:	34301

    Heres something I wanted to have done. Just be sure. Turned out to be quite expensive job.
    Click image for larger version Name:	Setecin kuvia 011.jpg Views:	13 Size:	1.45 MB ID:	34302
    Click image for larger version Name:	Setecin kuvia 016.jpg Views:	480 Size:	1.09 MB ID:	34303

    The result of pursuitig the lightest possible dampened crank pulley. Made with scientific method of sawing it in half. Now re balanced with the other bottom end bits. Saved 0,5 kg tough.
    Well worth the effort.
    Click image for larger version Name:	Setecin kuvia 018.jpg Views:	10 Size:	935.9 KB ID:	34304
    Click image for larger version Name:	Setecin kuvia 020.jpg Views:	6 Size:	765.0 KB ID:	34305
    Click image for larger version Name:	Setecin kuvia 047.jpg Views:	4 Size:	1.11 MB ID:	34306

    And finally after some hassle I have the clutch package.
    Click image for larger version Name:	Setecin kuvia 029.jpg Views:	12 Size:	979.2 KB ID:	34307

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    Re: 1.6 Zetec SE engine

    Oh and in order to further removing the rotating mass took away the oil pump gears and the pressure relive valve
    Propably useless but since they serve no purpose no point in keeping them in.

    Click image for larger version Name:	Setecin kuvia 052.jpg Views:	17 Size:	1.02 MB ID:	34308

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    Re: 1.6 Zetec SE engine

    nice rods/pistons....look familiar

    Great to see it comming together!

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by Moggy View Post
    nice rods/pistons....look familiar

    Great to see it comming together!

    They do don't they.

    Yes I agree. The head is nearly redy waiting for the custom cams. Cams are almost ready they only need the final grinding to be done.

    But then It'll still need all the electrics, and the Gearbox.
    Have something cooking with Elite Racing transmissions hope they can offer me what I need. Thanks for the tip Moggy.

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by Roadsport View Post
    They do don't they.

    Yes I agree. The head is nearly redy waiting for the custom cams. Cams are almost ready they only need the final grinding to be done.

    But then It'll still need all the electrics, and the Gearbox.
    Have something cooking with Elite Racing transmissions hope they can offer me what I need. Thanks for the tip Moggy.
    One of my guys is taking my transaxle down to elite this morning to be set up on their test rig.....(I damaged the actuators)....do you need any information collected whilst he is there?

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by Moggy View Post
    One of my guys is taking my transaxle down to elite this morning to be set up on their test rig.....(I damaged the actuators)....do you need any information collected whilst he is there?
    Thanks,not at moment no. Dean is looking through his storage to find casing and gear shift mechanism to convert the Sequential box to H-gate dog box. Only he was not sure he has any left since they really havn't manufactured many H-gate IL200 boxes.

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    Re: 1.6 Zetec SE engine

    Has anybody done much with the 1400 version of these engines?

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    Re: 1.6 Zetec SE engine

    Quote Originally Posted by Moggy View Post
    Has anybody done much with the 1400 version of these engines?
    Here in finland theres one 1.4 Puma rallying in the 1400 trophy series. So not very popular here. But then again my 1.6 is the first Zetec SE done around here that I know of.

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