zetecbeast

Hi guys,

managed to find this excellent forum in my search for information so here we go..!!

Ive just bought a kit car thats based off a 250 hp Zetec turbo engine.
Although I have only just (a day ago) aquired the car Ive decided although its quite rapid (750kg wet) I want a fair bit more.. Some of the examples of my car were powered by chipped YB cossie engines and were putting down some very impressive acceleration times and I'm wanting to see what I need to do to get the zetec up to 400hp +

This is what I know of it so far (I will know more once Ive had a proper look over it in the next few days)
It was built buy a guy called Keith, from a company called Alto Engineering. It was classed as a brand new lump in 1999 (out of 100 built)when the car owner bought it and had it fitted. The turbo kit was part of the engine package.
He cant tell me anything about the engine internals and I cant find any trace of Alto engineering. Apparently he thinks they may have started up with a new name.

Anyway, I have attached a pic of the engine but was wondering on recommended routes to get the hp I need. Ive built a few straight sixes and audi stuff, but this ones new to me.

Is it possible the engine is running a stock compression ratio? It has a Pectel standalone ECU!
I was thinking ARP conrod bolts, forged conrods and pistons, and ARP head studs and bigger turbo and injectors, then a remap (and check the fuel pump is up to it). Does anyone have any idea what sort of engines Alto built for this run? (eg it may already have forged internals *hopefully!*).
Is it possible to use a 2 litre zetec block and bolt my head and other bits to it?


Thanks in advance

zetecbeast

CrOwSoN15

May I ask what the car is mate? Or at least what it's meant to be

Also, it would more than likely be forged, I'm not too sure what the standard pistons would take, even if they've been skimmed.

It's an odd one if you ask me, never seen a Zetec mounted the other way around!

Ben.

zetecbeast

cheers
Yes, its a dax kamala. As rare as hens teeth but something I've always hankered after.
Anyway, can anyone help out with the required info or know a place that can?!!!

cheers

clarke5700

thats a silver top zetec (same as mine) goin by the inlet and the back mount im gonna say its out of a mk3 fiesta rs1800

see if it says HO on the back of the inlet

if its on standard internals 250 will be a good limit to leave it. have a look where the head meets the block to see if its got a decompression plate fitted it may have skimmed pistons of forged lol

clarke5700

and i bet its running an escort turbo exhaust manifold

zetecbeast

Cheers mate. I will have a look in the morning and take a few pics. If it is an escort turbo manifold what turbo flange would it be? Is it a t2.5 or t3? Thanks again

zetecbeast

And what turbo /hp is the escort manifold good for? Will I need to upgrade it and if so are there any decent aftermarket ones ?

clarke5700

its a t3 style. ive seen one at 400 at a push tho. i had mine to 300. what gearbox is it running? as i would worry about that first

zetecbeast

Thanks. I believe the gearbox is an mtx 75. Will double check. But it has custom big driveshafts and I'm hoping with the light weight won't give up the ghost forcing me to do a YB transplant! I want this zetec to sing, louder!!

clarke5700

screamer pipe?? if you have an mtx75 your onto a winner there

hogdog

The escort manifold is crap, you'll gain alot of power just by changing that, it gets more restrictive the more power you're running. Area six make one and there are more coming onto the market all the time.

The Zetec block and crack is capable of running massive power, 5-600bhp can be had reliably with the right mods so not much gain in swapping to a YB. One issue is the oil pump which doesn't like to rev too high, a well balanced engine will help with it's reliability but if you want to go past 8000rpm you might want to go dry sump.

If you want 400+bhp you're probably going to want to do some headwork on the inlet side, that'll help produce power without silly amounts of boost.

zetecbeast

Thanks mate. Thats good to hear that the Zetec will go BIG!
I am wanting ideally 450 hp.
As I currently have the 1.8 silver top zetec motor, is it well worth me changing this for a 2 litre zetec and doing the work to that? (unless mine is forged internals and then I will sacrifice the 200cc!!)

Do many people run GT30Rs or small housing GT35s on these motors?

I am not planning on running any more thna 8k rpm.

Is there any good guides for zetec turbo motors? thanks again

zetecbeast

An update.
Im now hunting for a 2litre blacktop. I am going to use the 1.8 oil pump and take the bits off my motor for the turbo conversion.
I am thinking of using C20 let forged pistones (2.1litre output I believe) although I am not sure I can live with the 7.9:1 compression ratio?
Conrods are going to be eagle forged ones.
New oil pump.
Custom exhaust manifold of some description.
Inlet manifold is ok for my needs from what I have read?
I might well get the cylinder head flowed and big valves installed.
ARP conrod bolts and head bolts.
Unsure on what turbo but a GT30 garrett or similiar.

Then to build it up....

Does anyone know of good zetec head porting shops?

thanks

dug112y

iTrader: (1)

ok 2 litre blacktop is a good start but your 1800 oil pump wont work on it.
c20 let pistons are ok but i dnt think the eagle rods fit those pistons without machine work, you would be better to buy a je/eagle package from the states.
get billet gears for your oil pump if your not going dry sump and get the bottom end fully balanced.
custom exhaust manifold...yes
What is the current exhaust diameter?
ARP bolts wont be needed,rods will come with bolts and std head bolts are good to over 500bhp
Inlet manifold will need replaced for 450bhp
neil roper or ian howell for the headwork.

i think you should be speaking to ian howell at area six mate. did you find out what gearbox it uses and does it have a LSD?

zetecbeast

cheers mate
I thought I needed to use my 1800 oil pump on the 2 litre engine?
I am going to get the pistons machines to accept the eagle rods, should be easy looking at whats needed.
Will look into the billet gears, thanks for that mate
Current exhaust is 3 inch downp all the way back.
Will look into replacing the IM.... how much can the stock IM support then?

I have looked at area six, they sell some nice stuff!! Will quite possibly contact Ian but need to do as much as possible myself to save costs..

it uses an MTX 75 and has an LSD

dug112y

iTrader: (1)

you need to recheck your sizes mate as you need to machine the rods not the pistons.
if your going for 450bhp dont cut corners,itll be an expensive mistake. get the piston /rod kit from america. IM only good for 320 approx.

zetecbeast

Cheers mate.
My mistake , yes , iirc it's the gudgeon pin holes that need enlarging on the rods?

I will look into a forged set from the USA but would use the mahle forged ones from the let if I can!

Didn't realise the IM could only do 320 . Better get spending!! Or might make a custom one

dug112y

iTrader: (1)

What turbo are you going to use? What intercooler setup?
450hp ain't going to be a cheap job and if your going about it by trying to use 2nd hand let pistons your going the wrong way IMO...it needs built with the right stuff and the pectel is a good start. Don't forget cams and valve springs too.

Get your engine out n stripped to see what you have?
Have you had it on the rollers yet to see what it's doing?

zetecbeast

Turbo will be a gt30 r , maybe a gt 35 r with smaller AR depending on the engines final spec.
Intercooler and so on is already on the car. It's a custom job. 100mm thick bar and plate , should be big enough for more power than I'm shooting for.... There's also a mocal oil cooler etc
I was going to use new c20 let pistons .. But will price up some as a forged set with the rods
It's a pectel t2 that it's running currently .
I will look into getting the valve springs and cams also, thanks. Im guessing area six is the place for them?

If I'm doing all that, and getting custom pistons (I would run a bit higher CR than the one I would get with the LET pistons) I might Even increase my goals slightly. If though , I could save significant cash by accepting 'only' 400 hp I would seriously consider it. Doesn't sound like that's the case tho..!
I am currently adding a new drive to my house so as soon as it's done I'm going to get the engine out and find out exactly what's been done.
I've got a rolling road printout from a dyno jet dyno with 242 bhp from the engine after mapping and the car runs accordingly.... (eg, its firking quick!).

zetecbeast

not relevent; deleted post

zetecbeast

Right, I'm back and needing some help from any Zetec gurus about how I should spec this engine. daily life has overtaken me for the past few months but Ive actually managed to get in the garage recently and see what Im working with.

The engine I think you are right clarke5700 is an RS 1800 one
It does have Ho on the inlet manifold but it doesn't have a decompression plate.

The exhaust manifold is a cast one but I don't know what its off. I can see the part number 434181-1 and AR 0-41 stamped on it.

Ok, so it either has forged pistons or skimmed ones... Im guessing the car cant run at stock CR even low boost without detonating ?

I am wanting some advice on what bits will work together nicely and heres where Im at so far.

I want a Zetec black top 2 litre engine (what years do these run between?) Theres a tubular ex manifold that I am interested in but is says to fit 00-04 ford focus?
Im guessing it will fit but need to be sure..!

linky to manifold

I know I need a custom inlet manifold

I have some forged pistons and rods sorted (black top)

New oil pump and timing belt kit

Do I need to get the head ported and polish and large valves?

Turbo a Gt30 or similar

I already have the pectel t2

external wastegate

wideband 02

My hp goal is around 400 hp.
.
All advice gratefully appreciated

ps/ Does anyone have any experience of live mapping a T2? I dont want to have to fit megasquirt2 but will if I cant base tune my pectel!

zetecbeast

Oh, I'm thinking of getting a ford connect van and dropping my 1.8t in that, I need a new work van lol