does anyone know how much needs skimming off the pistons of a 2.0l zetec block to lower the compression ratio? and do you use cvh or zetec head bolts?
does anyone know how much needs skimming off the pistons of a 2.0l zetec block to lower the compression ratio
i investigated this a while ago, and as far as my memory serves me the cvh ones are too short and the zetec ones are too long so either get the zetec ones professionally machined down or get hi tensile cap screws
calibra turbo pistons will fit with machining, or there are mahle forged pistons from burtons but they need the valve cut outs machined
1mm off the usual Zetec pistons.
You'll have a maximum of 1 bar, or you'll be risking a rebuild.
The block has to come apart for ZVH anyway, so you may as well get some decent pisons in there - Calibra turbos suitably modded, or some aftermarket Accralite, Cosworth, Mahle maybe even Focus RS pistons would fit (??)
What management will you be running?
chipped rs turbo management. for now.
The pistons in my 1800 ZVH S1 are skimmed 1mm
whatbost and power are you running?
Head bolts from a 2.5L Duratec V6......
I'm planning on building a 2.0 ZVH but I'm not sure how to solve the compression ratio issue.....
Maybe a custom made steel head gasket that is a few mm. thicker than normal.....
Every idea is more than welcome!!!!
Grtz,
Mark
i was told you can run up to 1 bar on standerd pistons head bolts i had normal cvh ones when i done a zvh conversion
Turbo compression plates are available for the 2.0 zetec.
But the block has to be stripped down anyway - you can't go drilling the block and leaving all that swarfe in there! That would be asking for trouble.
So while the pistons are out, either machine them down, or fit suitable aftermarket ones - the real question that needs ansering is do Focus RS pistons fit?
Head bolts - either use thinner washers and the normal CVH ones, or like Jim Hearne used, 150mm ones (are the Duratec ones that long?).
Seeing as the block will be stripped, it makes sense to bore it out to 2.1l, and get some weld built up on the CVH head to enable the safe use of Ford Mondeo gaskets - multi-layered steel should see you having no problems at high boost.
I'm just looking for a block, before the work begins for me. I'll be detailing the work, with pictures, I'm sure there are many things that I haven't considered yet!
Zetec 2.0 Multi-Layer (should still be OK for a 2.1)
FINIS: 1105772
BTW Mark you are the only other guy I know of in Europe doing this - I did hear that there is a N/A ZVH somewhere in Holland though. Over here (Deutschland) they all want Zetec Turbo - but hardly anyone has the balls to do it.
Hi Onujah,
I know i'm the first in Holland who is going to (try and) do this. But there is another guy who's thinking about it. Doesn't matter much in my opinion. When mine runs fine I'll be the first to try and help other people building one.
There is a N/A ZVH in Holland yes. It's in the track car of a good friend of mine. Runs really good!! (on Webers!) Build it all by himself. Only help was Jim's website!
Decompression plate is not the best way to do it in my opinion...
Yes, off course I'm going to strip the block down. But for me, no boring out to 2.1! The walls are already close to each other in 2.0 spec! Making the wall thinner will make me lose confidence in the whole thing.
Special "Burton" pistons are really expensive AND need machining. So I think I'll just machine the standard pistons down and give it a go.
The idea of welding up the head to fit a Mondeo gasket is a good one!!! My friend hasn't done that, instead fitted an american CVH gasket. (Felpro) Done one season on the track and bang....... he's running on the second one now...
(so on turbo spec this would be one 1/4 mile run and bang..)
Recently heard about a bloke in Belgium making custom steel gaskets. This might be a solution. (without welding the head)
For the head bolts, this friend of mine with the N/A ZVH has used Duratec V6 one's.... Works perfectly!
Where in Germany do you live? I live in the most southern part of Holland (Limburg) so i'm in Germany within 20 min. (and then have the joy of having no speedlimit on the "autobahn")
onajuh, did you say that you only knew of a few people doing this in europe? did u mean inc uk, cos i know loads of people that have done this.
i done the conversion my self with a 1.8 i had the head alloy weld at the back to cover the block had a plate made for the water pump for a fiver by some old boy got my uncle tap all the side for the water pump had to block off 4 oil ways at the front of the block file one of the fly wheel holes out the back breather on cvh you have to put on but i used the one on the front of the zetec this was in my convertible when it was i 3i good engine
I live near the Nürburgring Raceteack.
Sorry I meant Mainland Europe.
If you can find a set of Opel 16V turbo pistons (86mm) they can be very easily modified for a 2.1 - but if you're staying at 2.0 then you will probably be best machining the Zetec ones, because I don't know of any suitable pistons that you would be able to easily find without paying a lot of money for them.
So what management are you using Mark?
I bought the 2.0 zetec yesterday - gotta sort out collection now as it's miles away!
Possibly found some pistons from an Opel XE too....and should be getting a motor stand in the next few weeks.
At first the original KE-Jetronic....... When I get bored then it will be an aftermarket management for the big BHP's....So what management are you using Mark?
Where did you get a 2.0 Zetec?? And for how much (if you want to tell)
You live near the "Ring"..... That's really cool! Is the Ring open again for the new season or still closed??
Greets,
Mark
520 Euros - it's the usual price. 72K so should still have a good crank.
The ring opens again next month - check their website for details.
http://www.nurburgring.de/?rubrik=nordschleife&lang=eng
BTW any XE pistons will be suitable for turbo use, not only turbo ones - so the hunt for decent pistons shouldn't be too hard. The early XE's used forged Mahle pistons. Just look for 2.0l 20XE or C-20XE engines, found in Opels of the late 80's - early 90's. Here's a link with info:
http://members.fortunecity.com/ata/vectra/
Still be interested to hear about the Focus RS pistons - they should fit the standard 2.0 bore, possibly requiring no additional modifications to fir the Zetec crank...
I have now found a set of XE Mahle forged pistons, as well as OFAB. Work should begin in the coming months.
Pistons cost me 105 pounds posted, I think it's a reasonable price. The way things are going, I should end up with a good 250PS with outgoings less than 2000Euro. Hopefully be able to sell the unneeded Zetec head and ancilliaries for nearly as much as I bought the whole engine for...I'm gonna machine down the Zetec pistons and sell them to Zetec Turbo builders, to reduce costs even further.
Hi Onujah,
Are those pistons you've found "plug 'n play" or do they need to be machined as well? And do they fit in the standard 2.0 bore or do you bore out the cilinders?
Last but not least, do they come including rings for this price or do you need to buy them seperate and if so, what type of rings do you have to get?? (I mean from which engine type)
What will the compression ratio be with these pistons and how much boost are you aiming for?
Last saturday I bought a complete Zetec 2.0 wich has run 80.000 kilometres (50k miles) and the thing cost me only 295 Euro's.....
Greets,
Mark
They are XE pistons - the Zetec rod little ends will need machining, and the block will need boring out to 86mm. This brings the engine to 2.1l.
I think I'll need to bore some oilways into the pistons to provide lubrication, I'll see when the parts are side by side.
I'm going to have to consult the books and do some maths to work out exactly what compression ratio it will run, I'm guessing 7.5:1.
I'm looking to run about 1.4bar, should push out 220PS - 250PS - guesstimate. In the long run I'm hoping for more - but large intercoolers and turbos are a bit pricey, so I'll start small.
I'm not sure about rings - but I expect a set from an LET will fit the pistons, if not it'll have to be normal XE ones, possibly modified, I'll have to work that one out too.
Hoping to get a suitable camshaft made up from Farriday, with solid tappets, which will be run in on my current engine (1.6 EFI with 123PS). Turbo, intercooler etc will probably be anything I can get cheap from ebay, at least to begin with.
ARP's and good bearings will be bought, I'm trying to make the bottom end as strong as possible. I'm not looking for a high revving engine, just something which will take a bit of abuse.
Some uprated injectors will be needed, and I've already installed an uprated FRST fuel pump. Luckily the EFI has an adjustable regulator as standard.
Apart from that, it's just hoses and a good clutch. I'll take it easy on the gearbox (as much as possible), until I can afford something which can take the power - but really I'm getting a bit ahead of myself here, I'm still waiting for half these parts to arrive!
Anyway, I don't think there's too much to worry about with a 2.1 bore - I'd be more worried about skimming 1mm off the already thin Zetec pistons. Remember, the XE's are forged Mahle pistons - you can't ask for better than that. And you should be able to pick up a set easily. You already picked up a bargain Zetec - you could probably make money by selling all the bits you dont need. Don't forget, you need the Escort or Fiesta sump - I found mine for 30 Euros.
Have you seen the latest Fast Ford? There's a 1.8 ZVH with a Group A turbo, running OFAC, at about 0.8bar. I think it may be Marks who was selling bits here once, a FiestaTurbo regular. 215PS with more to come.
Sorry I forgot to mention - the pistons are second hand - I got them for 105 quid with rings, pins and circlips. Obviously I won't be using the rings
Check out the Accralite website - you can find details there of many pistons.
I've made a few assumptions, but 7.5:1 seems to be about right. It tallys with the figures from the Jim Hearne website, when using the same assumptions.
Here's the link:
http://www.dunegoon.org/compression.html
So the details of the future engine:
86mm bore.
88mm stroke.
55cc Head volume.
Gasket volume 5cc (guess).
Deck height 3.4mm (guess).
I'm just trying to find out if the LET turbo piston rings fit the XE pistons - any of you lot know?
According to PhilM, the LET rings fit - I went to Opel and they want 35 Euro for each top ring!
So, decided to call LOWMAN-JONES DEVELOPMENTS (0208 -592-1180) and have ordered a full set of TotalSeal Gapless rings for 120 quid - you can't beat that!
Just ordered a set of ARP rod bolts too, and got a good tip - you can use the Mondeo oil pump, it fits fine with a Renault Turbo GT oil filter - so that saves some more money
the cvh oil filter can be used aswell as its smaller.
got any pics of it mate?
What do you need a pic of mate? I've got loads of pics of the disassembled block and Mahle pistons, but the actual work is only just beginning...
I've also settled on a position for the breather, it's going on the intake side near the flange for the gearbox - where the block sort of curves. It is a flat area at an angle, meaning that the breather will be coming at a 45deg angle up out of the block - this should prevent any kink in the breather, it is also a little higher up so should always be clear of oil surges.
Also decided to leave the pistons as they are, machine out the little ends so the Opel pin floats, and bore an oilway into the top of the rod to provide lubrication to the pin.
Not sure if you know of this site...I had a little input into the build...www.jimhearne.co.uk (had a 2.0zvh in 1995 with cossie management after contacting Ian Howell of Fiesta Frenzy).
Thats the Bible of ZVH!
I have used machined cosworth pistons in mine for the reson that Ford have already spent a fortune on disigning a piston to run in a 2.0 turbo is more likly to be of higher quality than a after market one
Dan
what pistons, 2wd, 4x4 or escos?
Not sure I had the block built by PTS I'll try and find out,
This also takes it out to 2.1 and I seem to rememder looking into manufacur recomened over bore and it came in at the top over bore, so it means that you not exceeding the manufacurs limits to do this. Although your proberly pushing through double the recomended BHP
Some info here www.zetec-turbo.co.uk
Sorry to butt in but I do know of some zetec pistons, The Silvertop pistons are flat but the blacktop ones are slightly dished
Just to keep things updated...I now have a set of longer Eagle forged rods - they came with ARP's and only cost 350 bucks!! However, as they are 3mm longer (later Focus spec) I needed to get new shorter pistons. XE/LET/skimmed will no longer fit. So I comissioned Arias to build me a set to my specs, for about 600 quid. The savings made on the forged rods and ARP's convined me to do it - now the block itself will handle over 350PS (I'll probably never get that far, but anyway).
I have also brought:
Z20LET injectors - 16Ohm and 350cc@3bar. They'll do the job nicely.
Mocal oil cooler.
T3 with Cossie .48 Ex. Housing - adaptor is being built to fit a RST Mongoose system.
GRS intercooler and alloy rad.
-31 actuator.
AP Racing clutch.
Still lots of bits to get, but slowly it's getting there.
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