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Thread: Zetec Install

  1. #1
    World Champion Decade Plus User RChambers's Avatar

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    Zetec Install

    Right I probably should have taken photos whilst I was fitting the conversion parts but I can show some close up's of how everything fits once I clean my engine bay a bit!

    Anyway for starters here is the zetec sitting in engine bay with the gearbox attached.




    Once its all in position its a nice fit with a nice clearance from the bulkhead. It was a bit of a pain to get into position though. Easiest way was to fit the engine/gearbox as one unit. Got to be careful you don't crush the brakeline doing it this way. One thing that looks like it might be a problem is the zetec head covers the heater matrix inlet/outlet pipes a bit so I might not be able to run a heater (not that I was before ). I'll get this thread updated as I go along so that hopefully it can be a useful guide to other people. Next job is to fit the ST170 manifold and see if I can keep the standard master cylinder. It looks doubtful so I might have to buy a bias box .

    Richard

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    I love to crap Decade Plus User PercyBigun's Avatar

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    Re: Zetec Install

    hi, any progress with the inlet manifold and TB's yet?

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Zetec Install

    Percy I haven't got the manifold yet but from measurements it looks like the throttle body spacing needs to be increased. This is pretty easy apart from the fuel rail. I may block off the injector holes on the bodies and use the st170 fuel rail and injectors as this will be spaced correctly and also the injectors will be about the right size.

    Here are some pics of the throttle bodies. Not bad for 50 huh!








    Richard

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    World Champion Decade Plus User RChambers's Avatar

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    Zetec Install - Gearbox fitting

    Using the Retro Ford engine mounts the gearbox is moved forward by about an inch so the gearbox mounts and gearstick hole needed to be moved. Not that difficult but its useful information for anyone attempting this conversion...





    Gave me a chance to do everything properly this time! Luckily the prop still seems long enough with enough going into the gearbox. This is with a two-piece RS prop. Not sure it it would be better or worse with a one piece.

    Richard

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    I love to crap Decade Plus User PercyBigun's Avatar

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    Re: Zetec Install - Gearbox fitting

    looking good! they were a bargain for 50. how much could you knock me together a throttle body or bike carb conversion for mine and put it all on cos i am a car numpty lol

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    Pit Crew Decade Plus User ludsonline's Avatar

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    Re: Zetec Install - Gearbox fitting

    What GSXR are those throttle bodies off m8?

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Zetec Install - Gearbox fitting

    They are from a GSXR750. I think they are tapered from 44mm to about 40mm so plenty big enough for a 2 litre zetec. As for fitting throttle bodies to your car Percy... Have barely got time to finish my own and the mondeo engine bay is horribly cramped, so much so that I had to destroy the mondeo I had just to remove the engine And the engine is in the wrong way

    Richard

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    I love to crap Decade Plus User PercyBigun's Avatar

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    Re: Zetec Install - Gearbox fitting

    yeah really i should go for the supercharger (plenty of power available with the smaller pulley and water injection) but i am tempted by throttle bodies or bike carbs because its so much cheaper!

    however i have just shelled out on a unichip which i dont think would work on throttle bodies so i would have wasted my money, and the chip will work on the supercharger.

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Zetec Install - Gearbox fitting

    Done a little more on my zetec conversion today. Fit the inlet and exhaust manifolds today which were both thankfully perfect fits . Started my new wiring loom by laying out all the wires to where they have to go and then putting them through the bulkhead. Looking like a bit of a nightmare but once they are cut down to length and taped up it will looks nice and neat.

    Photos:










    Richard

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    Pit Crew Decade Plus User TepiTheFinn's Avatar

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    Re: Zetec Install - Gearbox fitting

    interesting.
    what is throttle size of gsxr, and does that rubber hose of st170 fit straigh on?
    Cheers,
    Tepi

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    Re: Zetec Install - Gearbox fitting

    looks good mate, keep the pics comin just so i see how it all fits

    will post pics of my progress on sunday. whats the reasoning behind making a new loom?

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    Pit Crew Decade Plus User Zetec_Escorts's Avatar

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    Re: Zetec Install - Gearbox fitting

    Looking good. I will be interested to hear how the linkages work out. My worry is that motor bike TBS will need less travel to get to full throttle which will need a bit of fabrication to sort out.

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    Re: Zetec Install - Gearbox fitting

    Zetec_Escorts said:
    Looking good. I will be interested to hear how the linkages work out. My worry is that motor bike TBS will need less travel to get to full throttle which will need a bit of fabrication to sort out.
    you mean the throttle cable will need connecting to a lower point on the pedal

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    Pit Crew Decade Plus User Zetec_Escorts's Avatar

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    Re: Zetec Install - Gearbox fitting

    That's an option, things are rarely that simple though.

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    Re: Zetec Install - Gearbox fitting

    cool matey, looks very sweet

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Zetec Install - Gearbox fitting

    The new loom is just for the engine management. TPS, injectors, water temp sensor, coil pack, crank sensor, etc . Lots and lots of wires, luckily they are all different colours otherwise I would be screwed! Tepi the throttle bodies are tapered from 44mm to about 40mm on the engine side. They will bolt straight on but the spacing is too narrow. It looks pretty simple to space them out a bit then the jobs a good'un

    Richard

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    Re: Zetec Install - Gearbox fitting

    Richard your going to need to put a return on that ST fuel rail if it's only got an input, the modern cars dont have a return to the tank the pumps are pressure sensitive and only deliver the correct ammount.

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Zetec Install - Gearbox fitting

    Hmm I haven't looked at it yet but there appears to be a pressure regulator. If not maybe I can use a cossie one in its place?

    Richard

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    Re: Zetec Install - Gearbox fitting

    Its not a pressure regulator its a pulse damper I think. Its the same setup on my Duratecs.

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Zetec Install - Gearbox fitting

    Ah its never bloody simple is it

    Would a cossie fuel regulator fit on the fuel rail?

    Richard

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    Re: Zetec Install - Gearbox fitting

    You will need to modify the rail, and if your not thinking of turbocharging then a EFI escort or fiesta one will do m8.

    Did you buy the manifold/fuel rail etc new ?

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    Pit Crew Decade Plus User Zetec_Escorts's Avatar

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    Re: Zetec Install - Gearbox fitting

    I have a cossie FPR to go on mine, and a EFI colgne one as a spare. It does not have to go on the fuel rail it's self. Just mount it on the inner wing and connect a high pressure fuel hose to it.

    Is your a 2 ltr? If not your TBs may be a tad to big.

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Zetec Install - Gearbox fitting

    Yep its a 2 litre so should be fine I hope . When I get paid I'll have to get some fuel lines and the regulator sorted. Then its starting time .

    Richard

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    Re: Zetec Install - Gearbox fitting

    What ECU you going to use ?

    i want to find an ecu thats fitted to a production car that can be easily modified.

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Zetec Install - Gearbox fitting

    I'm using an Emerald ECU. The software is really good and I've only heard good things about them. Everything seems really good quality so far. Only problem is trying to mount the water temp sensor. The only place I can think of is the fan switch in the water rail but this is after the thermostat. Do you think this would be ok?

    Richard

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    Re: Zetec Install - Gearbox fitting

    I would prefer to see it in the head, Ill take a look on mine tommorow and see if theres anywhere we can get one into.

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Zetec Install - Water temp sensor

    I know the original one is in the thermostat housing and I have a temp sensor there for the dash dial. Its too small to be able to take the ecu sensor though and you couldnt really enlarge it. Ideally I would like to drill and tap somewhere on the head but its knowing where to thats the problem lol. Plus I don't have a thread cutter that big .

    Richard

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    Re: Zetec Install - Water temp sensor

    I can send you a drill an tap if you cover the postage to and fro.

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Zetec Install - Water temp sensor

    Cheers for the offer, very nice of you . I'll have to get the thread measured on Monday then so I can let you know. This is a pic of the Retro Ford water rail. Don't know what the silver pipe is as that wasn't part of the kit I got .



    The top circle is the heater bypass and the bottom circle is the fan switch (not needed as ECU can control fan). I was going to use this switch to control a warning light on the dash. In the top section at the bottom you can see a standard temp sensor that works with the dash dial. Would be perfect to mount the ecu one here but then I lose the temp display on the dash and I don't think the hole could be enlarged enough anyway.

    Can I drill and tap a hole in the head whilst its fitted? Will the metal shavings matter too much or can you easily remove them when you are done?

    Cheers Clint

    Richard

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    Re: Zetec Install - Water temp sensor

    I would use a fan switch in the rail, I dont like fans controlled by the ecu as the engine gets hotter when switched off as the water stops flowing, it does circulate but much slower, the fan therefore may need to be on for a few minutes after the car stops, an ECU is normally powered via the ignition and therefore switches the fan off as soon as it turns off, however more modern versions may keep the fan switch powered, worth checking out
    The thermostat is in the right place IMO on that Retro Water rail though.

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Zetec Install - Water temp sensor

    Tidied up the wiring the other day. Had to keep covering everything up though as it kept snowing . Couldn't feel my feet by the end of the day. Wiring is done apart from fitting the relay box, plugs and finding somewhere for the water temp sensor. Gonna tape it all up once the engine is all running. Don't fancy having to unpick all that lot .







    Richard

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    Pit Crew Decade Plus User Zetec_Escorts's Avatar

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    Re: Zetec Install - Water temp sensor

    The silver pipe is to help you plum in the heater matrix.

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    Re: Zetec Install - Water temp sensor

    looking good mate, bet your itchin to fire it up aint ya?

    just one question tho, are you going to be able to fit pipes onto your heater outlets? it looks like you can. mine on the other hand are right behind the block and i dont think i will be able to do it!!!! im really puzzled now looking at your pics you are using the retro ford mounts arnt ya?

    keep up the good work

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    Re: Zetec Install - Water temp sensor

    Looks really good mate, can't wait to see that beast in action.

    Re the heater matrix, can you not pull off the bulkhead pass through and weld on 90 degree fittings? if you plumb them to offside of engine bay, you could run hoses in with room to spare...

    I don't think my car's gonna keep up

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Zetec Install - Water temp sensor

    Well my car spends half its time off the road so if you average the speeds then I think its about a draw . I am using all Retro Ford stuff and I don't think I will squeeze the heater pipes on. They might fit but if/when the engine moves it would snap the plastic heater pipes off! Not sure how I'm gonna get round it, might just take out the heater as the fan doesn't work anyway . Plus once I finish uni and get a job I might be able to afford a winter car!

    Richard

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    Re: Zetec Install - Water temp sensor

    to be fair i only need to worry about one as the rear of the water rail has an outlet for the heater so a small bit of pipe will sort that and iv got a few ideas about the other one its just a very tight squeeze.

    oh well these things are sent to test us. hopefully have all my hardware in this weekend and then iv just gotta plumb it in so to speak

    cant come quick enough tho

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    World Champion Decade Plus User RChambers's Avatar

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    Re: Zetec Install - Water temp sensor

    Good luck . Hopefully there will be quite a few zetec powered Escorts on the road by the summer. Then we can show everyone what an excellent conversion it is

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    Re: Zetec Install - Water temp sensor

    that depends mate mine might not be finished

    but eventually she will be on the road where she belongs

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    Re: Zetec Install - Water temp sensor

    RChambers said:Then we can show everyone what an excellent conversion it is
    Till the first cambelt lets go...


  41. #40
    World Champion Decade Plus User RChambers's Avatar

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    Re: Zetec Install - Water temp sensor

    Can happen just as easily on a pinto as a zetec

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