Originally Posted by orion_crazy_carl

right,if your using the 1.8 stuff u can keep the clutch and flywheel,its the same splines as the CVH box,so its easy!.wiring wise i had this loom last year in mine,buts its pretty easy again,u want a zetec without PATS really and u just got to find the powers and earths,haynes does help with tht bit!
performace wise,well,its a jump, the zetec runs so much smoother then the CVH, it responds lovely and looks good in the bay, this wasnt really done to go fast, it was more a modern twist on a 80s car,well 1990,lol,best thing of all, no more CVH tapping!!!!!

Originally Posted by orion_crazy_carl

hi peeps, been a few peeps asking about doing a zetec conversion in there mk1/2's onions and mk4 escorts, after reading FastFords terrible and expensive way to do it,i thought I would do my own way, cheaper, looks better and looks like it should be there, no bent pipes,no wires hanging out everywhere!!
its a pretty basic guide, any questions do feel free to ask!!!!right here we go;:
Attachment 110725
the car,1.6GHIA,non injection,if u have injection,it is easier!!!!
Attachment 110726
the engine!!1.6 carb power!
Attachment 110727
start stripping everything u dont need!
Attachment 110728
Attachment 110729
keep the fan,it goes stright back on!
Attachment 110730
pull the fooker out!

Attachment 110731
out!!
Attachment 110732
your then left with a hole like this!
Attachment 110733
we got the dash out for this one as the loom i had looks a lot neater behind the dash!!
Attachment 110734
the loom and ecu
Attachment 110735
this is ALL that shows loom wise under the bonnet
Attachment 110736
neat eh?
Attachment 110737
stick the dash back in if you have done it this way.
Attachment 110738
this is the 1.8 zetec engine out of a fiesta,all the brakets pulled off,u use the CVH alternator braket,use a CVH oil filter and cut the lug off the mount,either re weld or just use 2 bolts.
Attachment 110739
drop the zetec in,it goes in fine with the pulley attached,the trick is to jack the box up and put the engine in at a angle,we used the zetec flywheel and clutch and focus inlet manifold.
Attachment 110740
here it is!dropped in in its new home,snug huh!?
Attachment 110741
as for the alternator,the FF version said use the zetec one,ours didnt fit,so we used the CVH one,with the spacer from the zetec one with the zetec pulley,works a treat and u can use a std ford belt still!!the temp sender for gauge,join it to the non earth wire on the sender,to get the heaters working,block off the front hose from the thermo housing,run the back one to the matrix,and the y piece, block one end off,and the other to the matrix,perfect!!
Attachment 110742
top hose,instead of spending50 quid on a stat kit to turn the fan on,use a early escort zetec top hose, it has a stat built in!just join it to the original hose.
Attachment 110743
the bottom water pump hose has to enlarged to the zetec pump,use the original hose,cut the end off a zetec hose,and join.its a tight fit but works fine.
Attachment 110744
Attachment 110745
you can see the top hose,looks good,no bends or kinks.
Attachment 110746
if you have an injection the next bit is easy,modify the fuel lines to take the zetec push fit ends and fit a zetec fuel filter
Attachment 110747
join the return the end of the fuel rail,and the main in to the join under the manifold.
we had a carb car, so we had to fit the pump,tank hanger and lines.
Attachment 110748
here it is pretty much done!
Attachment 110749
the exhaust has to be modded to fit,but it sits in the right place,just to short!
Attachment 110750
here she is!!!all done and running,personnaly i think it looks the nuts,runs perfect and looks factory!!

here is the list and prices of parts:
engine-60 quid
tank,pump,lines and hanger-50 quid
oil filter-3 quid
manifold-50 quid
odds and sods-30 quid
time and labour-FREEE!!!!!!!!

as i said,its a pretty basic guide, but to be honest its a pretty basic conversion.If anyone wants and help, just ask!!!