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Thread: FIT A ZETEC - Part 3 - Engine Differences

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    FIT A ZETEC - Part 3 - Engine Differences

    Heres the third in a series to help anyone considering the Zetec Upgrade, I have compiled these posts from mainly information off the forums, so a big thanks to everyone who has shared thier data with us.
    I will be adding and updating these posts as we find out more so keep an eye on the edited date at the bottom of the post and reread it for the latest information.

    Currently the Zetec engine we are interested in has 3 main guises, all of which can be found in 1.6l, 1.8l and 2.0l
    variants, The later series 3 has a few different models. I am not going to mention the 1.6 as its not very tuneable,
    but externally the engine is the same as the others, main difference being bore size.

    Engine Data for Late Series 3 (earlier engines are similer):
    1.8l engine data:
    Capacity = 1796cc
    Bore = 80.6mm
    Stroke = 88.0mm
    Compression = 10:1
    Manufacturer Quoted Power = 116HP at 5500 and 160Nm at 4400
    Weight = 116Kg

    Note there are also a 105HP and a 130HP version of this engine, the only internal difference between the 115 version are the camshafts, the 105HP version had different pistons, cams and no under piston spray. Under Piston Spray can be added by fitting the jets as the holes are alreay in the block covered by blank jets.
    You can swap the cams from a 2.0 as a fast road upgrade on the hydraulic tappeted engines.


    UNDER PISTON SPRAY JETS

    2.0l engine data:
    Capacity = 1988cc
    Bore = 84.0mm
    Stroke = 88.0mm
    Compression = 10:1
    Manufacturer Quoted Power = 131HP at 5500 and 178Nm at 4400
    Weight = 118Kg

    Dimensions:



    Series 1
    How to Identify: Rocker Cover has "DOHC 16V" written on it.
    Known as the Zetec-E engine these have proved to e very reliable some covering more than 200K Miles.


    SERIES 1 'DOHC'

    Series 2
    How to Identify: Rocker Cover has "16V Zetec" written on it and the oil filter is atached to the oil pump.


    SERIES 2 '16V Zetec'

    Series 3
    How to Identify: Rocker Cover has "Zetec-R" written on it, some early ones had "16V Zetec" written on it like the Series 2 but the oil filter is attached to the block. The S3 engine also has the starter motor mounted high on the inlet side and due to this a Gearbox lug is missing.


    SERIES 3 Note Oil Filter on block and remote water pump.


    SERIES 3 Note Missing gearbox Lug

    These late engines are very different to the early ones a few differences noted:
    Revised Block
    Shorter Slipper Pistons
    Revised longer Rod
    External water pump
    Solid Lifters

    Series 3 ST
    How to Identify: Rocker Cover has "Duratec ST" written on it. Bulge aroun the inlet cam and on top of the cam cover.
    This engine was fitted to the Focus ST170, its the american SVT engine, 170HP with Variable Valve timing as standard, this enigne aparently has stronger rods than the mainstream models.


    FOCUS ST170 ENGINE

    Series 3 RS
    How to Identify: Rocker Cover has "Duratec RS" written in it.
    This engine is only fitted to the Focus RS, it is turbocharged as standard.


    FOCUS RS ENGINE
    Last edited by Clint; 07-09-2008 at 09:35.

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    Pit Crew Decade Plus User Zetec_Escorts's Avatar

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    There was also a 1.8 105 bhp version which was in early Escorts and the XR2i 16v. The 130 bhp 1.8 had a sysytem that sprayed oil on the bottom of the pistons, the other 1.8s didn't.

    The later Blacktop engines have the benifit of cheap performance parts available from the states, I have seen cam kits for as littles £210!!!!

    The engine codes are on my website if you want to make sure.

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    Cheers m8 ammended.

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    And, the 2ltr has a different pulley sytem that makes RWD fitting a problem. You either need to fit a 1.8 water pump or add an extra tensioner to change the dirrection of the water pump. I think it is only Mondeo 2 ltrs that have this problem.

    There are details at www.zetecinside.com

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    Isnt it only cars with aircon or/and power steering?

    I have both types of pump for the S1 and S2 engine in the garage you can tell by looking at the rotor on the pump, Ill document it when I am next out there

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    This is my year 2000 blacktop series 3.
    series 3 blocks have one gearbox mounting missing because of starter location.

    this is top view of same engine

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    Cheers Tepi.

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    Clint, what do you mean by Ladder Frame Main Caps.
    Help TheFinnBoy here

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    also the 2.0 has a bigger bore of throttle body than the 1.8 - not really an issue here cos most people doing a zetec conversion will be binning that and adding carbs or TB's or whatever.

    and the 1.8 has a lighter flywheel and different head which makes it more free-er revving.

    blacktop zetec has different position of sump recess to silvertop for the exhaust downpipe (silvertop is on the drivers side in FWD location and vice versa for blacktop). not sure about sumps on the duratec versions but IIRC the ST170 downpipe is on the same side as the normal blacktop zetec.

    another thing the ST170 has variable tract on the inlet manifold and bigger valves in the head, better cams, and a better exhaust manifold than the normal zetecs.

    for cheap performance cams for zetec from USA look here http://competitionwarehouseusa.com/ for "Comp Cams" or check out their ebay store.

    other good sites for zetec tuning bits:

    www.zxtuner.com
    www.focus-central.com
    http://www.jacksonracing.com/ (look under ford focus)

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc


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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    CAN ANYONE TELL ME IF THE CAMSHAFTS ARE INTERCHANGABLE
    BETWEEN THE BLACKTOP AND EARLY SILVER TOP ENGINES?
    MINE IS THE SILVER 16VZETEC / FORD ROCKER COVER.
    AND MUST SAY THE ZETEC PART OF THIS SITE IS GETTING BETTER
    WITH AGE:-)


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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    a mate of mine tried to fit my stock 2.0 cams (from my 1994 silvertop) to his 1995 1.8 silvertop - and they wouldnt fit.

    however i bought performance cams supposedly for 2.0 blacktop and they fit straight into my silvertop.

    so i assume this means all the 2.0 cams are the same from blacktop to silvertop, but some 1.8 cams arent - looks like you need the 130bhp/ps cams from a RS1800i fiesta if you want to upgrade 1.8 cams.

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    THANKS MATE JUST WHAT I WAS HOPEING FOR.
    I HAVE MY EYES ON SOME .
    ANY MORE INFO OUT THERE WILL BE MUCH APPRECIATED.

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    I think all series 1 and 2 cams should interchange, Series 3 Cams use different Profiles (Mechanical)

    There are 3 types of valves though, we found they list 3 different types of cotter pins in the book.

    Dont know why you m8 had trouble, they can be tricky to get in though.

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    It depends on the age, solid followers came in during 97 (?) and thats why you can't interchange them I believe.

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    if i remember correct, solid lifters and series 3 engines came in may '98

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    Was there any Series 2 Engines with Solids ? I havnt seen any.

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    in my opinion solid lifters only for series 3

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    now im getting confused

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    another question i am just about to fit a type 9 5sp
    i will be using a mondeo cover plate and a pinto clutch plate.
    i have read that a capri cct 133 quinten hazell bearing is ideal,
    however i have also read a cct 132 q/h bearing will also do.
    before i go and order one which one is the one to go for

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differenc

    my mate says the reason the 2.0 cams wouldnt fit in his 1.8 was there was a lobe on the cams and a sensor that screws into the head so it wouldnt fit.

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences

    I have now dismantled 4 different early zetec engines: 1.6 from Escort, 1.8 from Escort and Mondeo plus 130 hp 1.8 from XR3.
    Heres what I have found out:

    130 hp engine has different flywheel (with a recession for the clutch) and bigger stronger clutch labeled "low lift" (which matches the splines of a T9 box).

    130 hp engine has slightly different cylinder head casting with minor differencies on combustion chamber design.

    1.6 block is externally the same in dimensions as 1.8, but valves are smaller, the head has smaller ports and the oil jets in block are missing

    1.6 cams have about 0,5 mm less lift than 1.8

    1.6 and 1.8 flywheels are the same (except 130 hp version), cheapo 2.0i Sierra clutch disc can be used.

    Mondeo version of 1.8 has different water pump.

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences

    Quick question; What the differences between the Series 1 and Series 2? are rwd coversion parts the same?


    Cheers

    Dave

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences

    Series 1 and 2 (DOHC on cam cover and 16V Zetec I think) both use the same conversion parts. The main difference is that the hydraulic tappet system was improved to sort the sticking valve problem with the series 1 zetec. If you use 5W30 oil you won't have a problem with any zetec though. The only zetec that needs different conversion parts is the series 3 blacktop zetec

    She's built like a Steakhouse, but handles like a Bistro

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences

    The later black top focus engine has tapered valve springs with different caps. The were designed to be easier to open and therefore increase economy though reducing valve train losses.
    The down side is that in a performance situation they are shite! Adsolutly no good for anything over 6.5k. Early zetec E valve springs are the ones to use as they are good for 7.5k. You can feel the difference between the two by squeezing them between your fingers.

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences

    what different conversion parts are needed for the series 3? i know about the alternators but anything elsE?
    http://itsalmosttime.co.uk/blog/

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences

    Sump is different (different oil pump and pick up) and you can't get a reverse direction pump so you have to run an idlier pulley

    She's built like a Steakhouse, but handles like a Bistro

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences

    thanks rich sounds a lot of agg since ive got all the silver top bits
    http://itsalmosttime.co.uk/blog/

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences

    good info, i like
    My 3 door Cossie and Mk3 Escort Pick up Project...

    http://www.turbosport.co.uk/showthread.php?t=113630

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences

    does anyone know what engine was fitted to the mk5 fiesta 1.6si? was it a silvertop zetec or something else?
    just need to knoww if the pattern for the intel maifold is the same as the silver top 2.0.

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences

    I thought the si was a mk3 Fiesta... in which case its a gutless 1.6 silvertop zetec

    She's built like a Steakhouse, but handles like a Bistro

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences

    sorry it is a mk3
    i was just wonder if it would have the same pattern on the inlet manifold as the 2 litre silvertop in my mk1.
    They're dead cheap and would be fairly quick and easy to modify to allow as a manifold for a bike TBs.
    I would have bought one myself (£10 from the breakers) and checked if it would line up but my car is on axle stands in Ireland and I live here now so I only get to work on it some weekens now.

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences

    Yes they do fit on, although you would get more gains by fitting a standard 2 litre engine than you would by fitting throttle bodies to the 1.6 :thumb

    She's built like a Steakhouse, but handles like a Bistro

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences

    they dont mod very well anyway,i did one for r6 bodies. also smaller port size.

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences

    Thought I'd found a cheap alternative to ST170 bodies, ih well.
    How were the R6 bodies to use? were they easily split?

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences

    Quote Originally Posted by zetecdamien View Post
    Thought I'd found a cheap alternative to ST170 bodies, ih well.
    How were the R6 bodies to use? were they easily split?
    not too bad but a bit more bulky and not as neat. i brazed the fuel rail to suit as its steel.
    also shown is another slant, ie cut down webers adapted to an escort inlet.

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences

    so can the 1.6 silver top be directly swaped for the 2.0 zetec? provided that the sumps and oil pick up pipe is changed.

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences

    Yes the base engines are exactly the same other than bolt on bits like manifolds and water pumps, etc.

    She's built like a Steakhouse, but handles like a Bistro

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences

    dont know if they have been mentioned before but wats the bore and stroke of both the 1.6 and 1.8 silvertop engines??
    1973 mk1 escort
    1982 Toyota corolla ke70
    1988 mk4 escort

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    Re: HOW TO FIT A ZETEC - Part 3 - Engine Differences


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