Heres your answers..

To fit a 2l zetec into a escort you need the following from a 1.6-1.8 zetec escort.
Water pump
Sump and oil pick up pipe
Oil pump
Clutch and flywheel
alternator and pas pump along with the mount they sit on
Exhaust manifold
Inlet manifold
Escort zetec engine mount
So basically take your 2l strip it down to a bare head and block and fit the above

Your diesel engine has a ib5 box with a front mount starter as where the zetecs are rear mounted, Im pretty sure you can take your speedo drive from your box and fit it into the escort zetec box. If not just swap the gearbox bell housings over, An escort rst lsd with fit your ib5.

You will need a petrol van fuel tank which are £90 upwards, you will also need petrol fuel lines ( hatchback ones fit )
You will also need to fit the engine and interior wiring loom from a petrol zetec to run the engine and also a non pats ecu from a mk1 mondeo.

The codes on the ecu you need are DESK ,DEEP DEWY and they can command a fair price as they are getting thin on the ground.


I have learned pretty much on the go as this was what I was going to do with my van but I gave up and went TDI, Im sure I have missed bits so someone may have more info on the subject.

Hope this helps