Right I'm looking to put a zetec engine into a MK4 escort bonus and need some help on a couple of bits.

I've got a 1.8 zetec 115 ps from an escort gti which I will be running on the standard ecu. I'll be using the fuel tank from a late model XR3i for the return fuel lines and I've had a top cvh mount made up to accept the engine just need some advice on other parts.

The engine came with the gearbox but no driveshafts so I was wondering what driveshafts I would need and how I would go about linking up the speedo and a rev counter as its the 1.3 carb it has no revcounter. Also what radiator would I need.

If anybody thinks of anything I've missed please let me know as I'm keen to get this going


Cheers

 

Hi mate, done this a few times so will help as much as i can.

I'm not sure about GTi box to be honest, dont know if mk4 shafts will fit it, plus the rear starter location could be a bit tricky. I'd advise using a mk4 box (any will fit but RST would be preferable as has LSD) as its a straight fit to zetec, and obviously original cradle, shafts, speedo drive and linkage can be used.

Rev counter is a bit harder, i'm still tryin to get mine to read correctly, if your using full GTI loom and management it might be a bit easier.

I run an XR3i radiator in mine with a bit of fettling to get hoses to fit neatly - its worth noting that the Zetec's run hotter than CVH's so dont worry too much if temp usually sits midway.

I run a 2.0 in mine below:




any pics of yours?

 

you'll get plenty inspiration and tips in here too

https://passionford.com/forum/other-...ar-thread.html

 

Use the original box and shafts etc, make the job easyer. As said above s1/2 rst box with lsd best bet, but hard to find a decent one these days.

As for radiator, ideally a one from a 1.6 mk4 escort, or any similar sized one really with the right outlets. I think saxo ones fit nicely

 

Yeh I was thinking of going with the XR3i rad aswell or an rs turbo item as I'm told there basically the same.

I would use the original box but its a 4 speed unfortunately so I will have to ditch that. From the looks of things the box that came with the engine has the same location points for gear selectors and clutch cable so I will try and use that with the driveshafts that I already. I was just a bit worried that the standard shafts wuldnt take the power but I'll try them out.

Where did u locate the fuel pump and filter? I'm also told that the plastic inlet mani's on the zetec's are a bit of bugger to fit in a MK4.

 

Speak to Twins, they just done one

 

Ok mate I'll get hold of them for some advice cheers for that

 

as far as i'm aware all mk4 shafts are the same fitment/strength. I'm using 1.3 ones in mine above and never misses a beat.

I'm running a XR3i efi tank with pump inside and have mounted filter here:



not sure about the plastic manifolds, i know the mondeo ones dont fit at all. Think the Escort GTi will fit but better off using the metal inlet like mine above if you can get one.

 

I used a turbo fuel pump and cradle set up ,turbo tank ,rst box and driveshafts ,for the rev counter bought one from rally design and wired it in ,just need to trace the green wire in your engine loom

 

Thanks for all the advice guys this is very useful.

So the standard driveshafts will do the job no problem. I've heard there are variations with the tanks on the MK4 so I will probably go with an XR3i tank due to it being fuel injection and then an rs turbo pump should be able to get them for peanuts second hand.

Twins I was thinking of goin with an aftermarket rev counter because its just a case of wiring it up and they look quite nice on the dash. I'll stick with the standard inlet unless I see a cheap steel one goin spare.

I was thinking of makin some very basic mods to the engine before it goes in just to improve response as in a minor rebuild i.e bearings and seals gaskets and timing belt etc. I will probably get my cousin to do some light headwork and have the head skimmed and some 3 angle valve seats, a reworked mondeo 2 litre throttle body and an air filter so pretty basic stuff.

Any other suggestions for light upgrades?


Cheers

 

will an xr3i rev counter not work if you use the rev counter feed from the zetec loom?

 

As i said, over the years of messing about with mk4's, never had a problem with shafts. Even the 4 speed ones fit in 5 speed boxes and vice versa.

Would deffo recommend putting a timing belt kit on while engine is out, as its pretty tight when its in! a 4 branch manifold makes a massive difference on a zetec if you can afford it the now.

 

Yeh the current box is a 4 speed so its quite nice that I can retain the shafts which will save me a few pennies to spend on something else.

Will definately perform all the work to the engine before it goes in the car to make life easier. I was thinking of exhaust systems but if its fairly pricey I will just get that done at a later date. Ill probably go with a lightened flywheel aswell to improve the acceleration.

 

the four speed box even bolts straight up to zetec no prob, my mate ran one in a Bonus track car on an 1800 zetec running a single carb, used to fly round Knockhill!

a budget lightened flywheel would be the one from an EFi mk4 XR3i as it has the pick up for flywheel sensor and it much lighter than zetec one - you have to bore the bolt holes out very slightly though

 

Four speed box sounds like a laugh would probably do 70 in second lol

How much lighter is the XR3i flywheel than the zetec item then? Its just I've heard if u have them too light u actually damage the performance. Not doubting your knowledge just curious as all the little things I can do to the engine without spending mega money are welcome.

 

So has anybody got any recommendations for performance exhaust manifolds for the zetec engine??

 

there are arnt many flywheels out there that are 'too' light, what you get is a loss of revs up hill with constant throttle position.....you wont notice this with a lighter one. id be suprised if you could find one that made this much difference tbh

you will need the 2l managment, cams and MAF to make the most of the engine too, and once you have the 2l managment theres no problem if you decide to put a 2l bottom end on....

the inlet of the 1.8 just squeezes in i beleive, the 2l wont fit.

as for manifolds, ashley are good but arnt stainless steel, you can get kits to make your own if your up for a bit of a challenge but most aftermarket ones are good, just try to make sure the headers are of as equal length as possible

 

I'm getting the flywheel lightened and balanced so ive covered that area.

Will be getting some light porting done to the head with a polish and finally a skim to improve that side of things, will pop a 2l mondeo throttle body and a K&N on for good measure aswell.

Ive heard about putting the 2l cams in the 1.8 and running it on 2l management but how successful and will it run smoothly thats my concern.

If i was to take that route would the 2l management work on the standard 1.8 or would i have to buy 2 lots of ecu's and looms?

As for manifolds im not at all bothered about what it looks like as long as it does a gd job and doesnt crack, it will be heatwrapped anyway so it doesnt matter if its stainless or not.

Whats your say on exhausts?


Cheers for the advice by the way jammerss much appreciated

 

Ashley 4-branches seem to get a good reputation for Zetecs, one of my winter jobs for sure.

http://cgi.ebay.co.uk/ASHLEY-PERFORM...item5193fc094a

 

Yeh I think I will go with the ashley item its £200 on burton power which comes fully assembled, they also do an ashley single silencer exhaust for the mk4 aswell which is about £180 which shuld sound pretty meaty.

If and only if I were to go with carbs at some point would I have to run it on standalone management or are any of the zetec ecu's capable of doing the job? If so megasquirt seems to get a good write up on here so I may go with that

 

ive got an ashley 4-2-1 manifold and exhaust on my 2litre zetec, sounds lovely.

 

to run a carb or carbs on a zetec, the budget way is to use the original loom from your bonus - the engine loom (which unplugs from the main car loom behind the passenger headlight) has the plugs etc to run the zetec because the Bonus engine uses a coilpack and flywheel sensor like the zetec. Its not as good as aftermarket stuff like Megasquirt or Omex but its good for gettin it up and running. This way is popular with the stock car boys cos its cheap and easy.

My mates that I mentioned before that ran the 4 speed box made 129 bhp from an 1800 zetec with 2.0 cams, 4 branch and single XR2 weber carb - and used the Bonus loom to get it up and running

Another mate (think his username is Marv on here if you search for it) has my old bonus and runs a 2.0 with single carb with this wiring as well and his goes very well and runs perfect.

There is also an XR2 in the for sale section on with a zetec & bike bodies that uses this wiring set up - most folk call it the ESC set up i think

Rosco

 

That sounds like a plan I'd love to get a carb setup on the go purely for the noise and they give good power figures.

Also on the cams I assume your talking about the 2.0 ones from a mondeo silvertop. If so are they a straight swap or is there a bit of fettling needed to get them to fit.

I'd like to make 130 bhp which I think is do-able with a skimmed head, light port n polish, lightened flywheel, cams, 4-1 mani and exhaust and a single carb. Any other suggestions are very welcome.

Cheers for the advice rosco your a gd man lol