Fizzy T

Alright guys just wondering if theres an indepth zetec turbo guide anywhere for people who want to DIY it at home in their garage?

If not why dont we collect all the best information here for Budget and Advanced stages of build here?

Reason I'm asking this is I'm collecting parts to build up my own ZT in my xr2i but you hear so many peoples different views on what to do that most of the time the best advice can get disregarded or lost in translation etc.Now I have the money to buy the major parts of the conversion I need to find out what are the correct pistons I need to buy.Doing this guide would help out loads of people.

I have heard the zetec blacktop is the best base engine to start with if not doing a build on a budget so I'm going to aquire one of those,I do already have a silvertop but I'm going to rebuild that myself to a standard spec to put into my fiesta quartz XR2i rep.

I know this is alot of writing to read so I'll come to an end now but one last thing could be for example in the guide we could point out this lot...

1.Oil breather locations in block *when blocking the OE breather port and creating a new one,pictures would really help instead of people just saying tap into the block*

2.Rod and Piston choices,tips like cant mix silvertop and blacktop parts here?Apparently?

3.Compression Ratio choices?

I hope people will be willing to help

zetecdan

theres a guide here but i havent turboed a zetec so cant comment if its any good or not.looks like a budget option.

http://www.turbo.me.uk/?p=home

Fizzy T

Yeah read that one before.Most of the guides you find only say the basics and dont have many pictures to actually show what they mean.

Red16

Dont take this the wrong way but this subject has been covered time and time again... the information is there just do a search, plenty of threads with photos and descriptions on this forum and the other related ones... eg fiestaturbo.com etc

project rs

firstly get a black top engine strip it down bin rods and pistons and order the je/eagle combination, have crank checked engine bored if need be to go with piston choice, order a set of valve springs from area six if you want to run over 12 psi safely rest of head good for 350bhp as is, for the fiesta you'll need a modified engine mount some type of custom manifolds or the head re tapping to accept the turbo manifold of a series2 and a rover inlet, the sump that comes with engine can work with normal ib5 starter position you just need to cut the front section out that would normally bolt to the mtx gearbox unless your using that too, as to oil return for turbo this can be put in block or welded into sump depends a lot on whether you are good with welder or simply going to get it all done by someone else. now to comp ratios your standard head is 48cc's if i remember right so worth ccing it just to see if it's been skimmed or after you've had it skimmed and you'll need the deck done too as the metal gaskets need a true mating surface to seal properly, you can use the st170 head gasket, focus rs or one of ferriday to achieve your desired ratio after you've done some of your calculations, unfortunatly not got any picks but will try to give you as much help as you need as you come to it or take a picture of the bit your on at that time i'e mount etc, please add or correct if any one feels this is wrong

zetaboostboy522bhp

hi mate first of all the silver top has much bigger main bearing cap so it the best bottom end , but the black top has a sligthly better flowing head and the st170 even better. i would personally say that the black top engine would be the way to go as they are widly available , have a baffled sump as standard but you would have to make custom engine mounts. if you start swapping heads you have to start custom mounting pulleys etc so it aint worth the trouble. your from lincoln which is a shame as the best zetec tuner in the business has just finished and hes not doing engine builds anymore but he is still selling components. speak to ian howell at area six on tech@fiestafrenzy.co.uk he is a very helpful guy.

first you need to tap the back of the block for the breathers ports , here in the pics





you want arias pistons and eagle rod package pm me and i will have a word if you cant talk to ian via email . the compression ratio you need is 7:45:1 , a rebore of the block to 2.1 litres all new bearings etc. you will need a new 2.0 oil pump , a 1.8 zetec water pump , arp head bolts , 2.0 multi layer metal headgasket as these are the same as the wrc items but make sure its a genuine gasket and on the head side you just need uprated valve springs for some decent boost max 20psi , an rs1800 high output manifold and a decent set of injectors/ new fuel pump/ fuel pressure reg and an escort rs turbo exhaust manifold . at this stage you should use pectel engine management as reliabity usally comes and causes people major running issues. at this stage on a t34 turbo running about 20psi you should see a genuine 300bhp
after this , this is where it starts getting very expensive , custom inlet manifold , big throttle body , 650cc injectors , 3 bar map sensor , fuel pressure reg , big valve cylinder head with double valve springs and custom cams, venier pulleys , tubular exhaust manifold , gt30/ t61 turbo , external wastegate , with all this you should see 500+bhp @ 30psi but at this stage of tune you should have the engine put on the engine dyno to test each component.
your looking at the best part of £10,500 for all this mate



it all depends on how much bhp you want and how deep your pockets are!
to be honest you need to build the bottom end and then add to it as you want to as thats what i did.
hope this helps and let me know if you need any help
cheers paul

XRT_si

iTrader: (2)

All above is good advice. I am using a silver top bottom end with ST170 head, as its a good combo, but finding trouble with the cam belt

Fizzy T

My collection of parts currently stands at...

* Brand new GT30 exturnally gated turbo.
* Eagle con rods.
* New Fiesta/Escort 1.8 Zetec water pump.
* Rover turbo inlet with Ian Howell adaptor plate.
* ARP head bolts.
* ARP main cap bolts.
* ARP flywheel bolts.
* Bosch Electric Water Pump
* 2.0 Silvertop *this is going in my other car now though as my ZT project deserves a blacktop.

Currently have £1000 saved for ZT parts and Ian would be my preference of people to call but due to his recent business closure I've been leaving him be.

zetaboostboy522bhp

email him mate as he is still selling off the shelf bits. all his pistons are custom built to the spec of the engine just incase the block has been decked etc, tell him paul cheshire sent you from derby