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;:

the car,1.6GHIA,non injection,if u have injection,it is easier!!!!

the engine!!1.6 carb power!

start stripping everything u dont need!


keep the fan,it goes stright back on!

pull the fooker out!


out!!

your then left with a hole like this!

we got the dash out for this one as the loom i had looks a lot neater behind the dash!!

the loom and ecu

this is ALL that shows loom wise under the bonnet

neat eh?

stick the dash back in if you have done it this way.

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.

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.

here it is!dropped in in its new home,snug huh!?

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!!

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.

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.


you can see the top hose,looks good,no bends or kinks.

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

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.

here it is pretty much done!

the exhaust has to be modded to fit,but it sits in the right place,just to short!

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!!!

 

Good write up there mate!!


Looks nice!

 

thanks bud

 

That looks the business mate, you obviously know your stuff!

 

i done a zetec conversion on my orion last year,the one in my sig,learn ya go mate,best way thanks

 

Excellent write up!!! Few question though

Im sure i read somewhere you need to change clutch? but looks like youre saying it will all just bolt upto the cvh box?

On the wiring side how difficult is it? Is the fiesta engine loom and ecu all one piece meanin you just need to run a live and earth to it?

And lastly how does it perform compared to the 1600 CVH

 

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!!!!!

 

Excellent mate very much appreciated, Mines already injection I want to go 2.0 but it makes sense to go 1.8 first as i need the sump etc and hopefully the ecu will swap over pretty easy, Must be more torquey than the cvh.

Is there a easy way to see if the car has PATS

 

1.8 is good,been told its better thn 2 litre?mine was 2 litre b4 i go zetec turbo,was superb.not to sure with pats,guessing all mondingos have it,sure early zetec fezzies dont??not 100 sure tho,u can always go MS management!!

 

Cheers would like ms but it scares me lol , Read a few how to conversion and no one seems to mention PATS better look into it as theres plenty of zetec conversions kicking around.

 

nice 1

 

do you want to do mine for me been thinking of this but wouldnt have a clue how i got efi xr3i ?

 

its just the same mart,its a pretty simple conversion,i only way i learnt was doing it!

 

Nice one Carl... Turbo'in it now are we... not supercharging it??? Well done mate...

 

to much hassle for super charger,space is an issue!so turbo all the way

 

whens the turbo version coming lol

 

Whens it gonna be done for? You changing pistons and rods?

 

Excellent guide there mate, well done to you.

 

done 3 guides of the turbo conversion already

as for the zetec turbo not 100% sure what im gonna do yet,I know what managment and inlet and zorst im using,just what it middle not sure of!!
cheers mike

 

Another quicky why did you use focus inlet?

 

Nice one mate mite consider this for my mk3 xr3i.They should make this thread a sticky

 

manifold wise i used the focus one as it fits and i was told the mondingo one doesnt,it touches the brake bar,not to sure if thats true,the other zetec manifold is supposed to be better,flows nicer??if u look at the focus and mondy ones go all over the shop,so i can see why there not as good,but i prefere the look of them to the over cam cover ones!
well recommended dakar!

 

dont suppose u could help me with this problem please mate?

https://passionford.com/forum/showth...tec+conversion

 

pm'd bud!

 

yes cheers i shall have a play tomorrow....

 

I,ve just done this conversion in my m4 escort cabriolet.
my donor car had PATs So I just followed the wires from the ecu up to the steering colomn and removed the whole thing. basically it is a ring shaped sensor around the ignition barrel that senses the proximity of the chipped key so the ecu only functions when the correct key is in the ignition. so to cut a long story short I taped the key to the sensor ring and put it with the ecu in the glove box, works fine.

 

that the same how i done mine fella, just put my ecu behind the battrey and got a loom made for Ł50, so it was just join 5 or 6 wires. mint cost me a grand total off Ł300 inclulding buying the car and all 130bhp stuff

 

good guide =)
anyone know where you can get LONGER HT leads for these engines?? i cant mount the coilpack where its suppost to be RWD capri, cause the bulkhead is in the way!!!

 

awesome

 

Apparantly PATS can be disabled, if anyone knows how i would like a pm as im on the look out for zetec and knowing my luck it will have it lol

 

good conversion there!!

 

can you post a pic of the modified mount ;P

 

would like a bit more info on wiring please!! i just changed the gasket on my old mk4 escort van 1.6 cvh on carb, its the first time ive ever looked inside an engine an i found it piss easy! think i could do the zetec conversion if i new more about the wiring side like what do i do with the original loom, ecu`s an what do i replace an how. Sum1 said they got loom made up for Ł50 an there was just 6 wires to join does any1 still make them up? cheers

 

It's a bit more than 6 wires to do it properly, there's a mini fusebox to keep the feeds for the lambda, ecu and coilpack safe, a main ignition relay, a fuel pump relay, a few wires for guages. I do a labelled standalone loom for cvh/ohv replacement, kitcar, even runs it on a bench if you give it live, earth, fuel and flick the starter. Pm for details or I'll have to register as a trader?

 

briliant post m8!! im thinkin of doin the same on my mk4 van but using the 2.0zetec (would it be the same to fit). my vans a 1600cvh on carb its been a bit of a project ive lowered the back 2day just the front to do now, then i think im gona go for the zetec i think i get how to do it the only thing is i dont have a clue about ecu`s an looms including dash ive never done that sort of work b4. supose i start and get stuck would u help please
cheers m8
p.s if i used carbs(twin webers) would it be easyer
thanks again m8

 

glad people are still finding this helpful

modified mount is just a chopped normal one,lol
the 2 litre like in my red one is more of a pain if its out of a mondingo,i got a focus one which was a straight fit!!!
wiring wise i had a made up loom from my other orion i zetec'd so it aint really much good as its a custom one.
when i do the next one i'll just get megasquirt on it,easier to wire up and then in mappable to.
if u run carbs u still need signal for the coil packs,heard somewhere u can use a HCS coil pack loom with edis to control it??not to sure tho

 

Cheers m8, so basicly if i get the focus 2.0zetec and run it on carbs all i need 2 do is alter 1 engine mount the hose`s and sum sort of signal for the coil pack(is this the coil pack from the focus zetec)....
1 more thing m8 would i just use all the things off the focus zetec to ie water pump etc etc
Cheers pal very big help

 

yeah the focus 2 lite is very much similer,heres a couple of piccys of my red one with said engine in:




use the water pump ect no problems

 

i have an escort 1.6 ghia auto can u do a ztec conversion on that buyt keep the auto box or will the auto box not be able to take the torque my pics of my car are up if like to take a look

 

Well spurred on by this thread i now have a 2.0 Zetec with 1.8 bits already on, Like many stuck on the loom side thought i had it sorted then realised the engine loom i have bought has had some bits chopped off mainly edis plug , lamba wires and air sensor plug Not sure whether to cut plugs off a scrapper or get another loom ?