xr4x4rs

iTrader: (5)

as title

i have been trying since 11am to now to try and get this engine in

the problem im having is i can get it to line up to the box but the bolts go tight and wont do up anymore and theres still a gap

now im using zetec clutch and my original release bearing as the zetec one is bigger than the input shaft

also the water pump pulley rests against the inner wing

i want to know is

what clutch and bearing do i use

and do i modify the chassis leg for the water pully

any help please as car is stranded round my mates with engine half in still on hoist

and ned the car by tuesday

thanks rich

studabear

have u checked the clutch on the gearbox splines

xr4x4rs

iTrader: (5)

clutch lines up ok

but engine wont pull up to gearbox by about 1cm

im thinking its something to do with release bearing

but need someone who has done this conversion so i know what to use

also if anyone has a pic of drivers side inner wing showing engine fitted with water pump pulley on

can you please post it up

thanks

studabear

whip the bearin out an see if it goes rite in pain i the backside but atleast u will know

Sketch

What flywheel are you using?

I use a complete RS Turbo clutch in mine.....

tonyturbo

me to

Matt Lewis

iTrader: (2)

Have you damaged the splines on the clutch plate

Matt

xr4x4rs

iTrader: (5)

im using zetec flywheel

is this wrong then

please help

what exactly do i need to use off a mk4 onto this engine

thanks

Sketch

Isnt the right flywheel the FRST one with the bolt holes enlarged slightly?

Then the RS Turbo clutch bolts straight on.....

xr4x4rs

iTrader: (5)

thankyou mate

just had a pm off tonyturbo and explained about the clutch senario

ive always been led to believe everything would go in smoothly well today didnt but tomorrow its going in no matter what

thanks again guys

DOO

I used a RST flywheel when i done mine

richm

we used a 1.8L Zetec flywheel and clutch and original Escort g/box, release arm and bearing. This was on a Mk3 S1, but can't see there would be much difference?

here's a view of the fitted clearance in the MK3 :

xr4x4rs

iTrader: (5)

yes thats a bit of clearence there

i havnt even got quarter that i dont think

i will c tomorrow

ive tried using all zetec stuff bar release bearing but it wont have any of it

so gona put mk4 stuff on and try that

richm

there are a variety of photos here - www.zetec-turbo.co.uk - in the gallery if it's any help?

James

That'll be because you have a 1cm gap between the box & engine.

When you sort out the clutch/flywheel issues and the engine will move more to the left leaving more room for the waterpump on the right.

xr4x4rs

iTrader: (5)

ok engine is in

what do i do with the alternator

which one do i use

as im stuck on this now

the pully off the zetec doesnt fit the cvh alternator and the zetec wont fit on the cvh bracket

so do i need to use the ztec alternator and bracket?

richm

use the zetec alternator and (Escort) Zetec bracket -

xr4x4rs

iTrader: (5)

right engine is in and fires up

had to use my mk4 engine loom and lenghten a few wires

then it would fire but wouldnt tick over so put zetec ecu and iy purs

question is now

ive fitted all the brackets and alternator but what fan belt do i use?

and what water pipes as the zetec has a very large outlet from the pump

ive had to cut and shut a lot of pipes and move my rad right over so the bottom hose isnt kinked

looks a rite mess in there but its the best i can do with what ive got

any suggestions

richm

is your pulley arrangement the same as my pic above?
That belt is a Gates- 68401

xr4x4rs

iTrader: (5)

yes it is mate

what sort of belt is that

any name off a car or the length of it

richm

The Gates "68401" reference number is definitive, if you go to a motor factor who stocks Gates belts and ask for that number you get the right one. We just had a few away and tried them to find the right length
In principle it should be for a Escort Zetec WITHOUT power assisted steering. We didn't bother back-referencing the number to an application...

xr4x4rs

iTrader: (5)

ok mate ill sort that out tomorrow

also who put the bolt in on the alternator of that pic

as its the wrong way round lol

richm

?? bolt? which one? wrong way?

xr4x4rs

iTrader: (5)

first pic

its the big long bolt that holds the altenator on, top one

if th ealternator goes the how will you get that bolt out due to chassis leg in the way?

also what water pipes are used fro the water pump

thanks

richm

ah.. LOL sorry, see what you mean.. getting that bolt out was the least of the problems if stuff needed getting out of there
we used a Zetec water pump hose - was a tight squeeze to get it to go from the pump to the rad, and needed to be trimmed a little short on the pump end to get it to fit half handy. This hose also has a T-stub moulded in that goes into the cross-tube that runs along the slam panel. (goes to the thermostat housing from memory)

xr4x4rs

iTrader: (5)

what ive done is

used the zetec water pipe and moved my rad right over so theres no kinks in the pipe


now the original cvh had a pipe that went upo drivers side inner wing which im not using now ive turned the matrix pipe round and the two matrix pipes go to the stat housing now

and that pipe that runs a long th eslam panel is the same except goes to my header tank and the one that goes to the heater pipe is blocked off

does that make sense

xr4x4rs

iTrader: (5)

also where does your header tank feed go as im using the efi mk4 which is on passenger inner wing and goes to that metal pipe then goes to water pump

will c if it works tomorrow

xr4x4rs

iTrader: (5)

im still struggling on a fan belt

ive tried 10 on today and there all to small or to big

the problem im having is no one stocks gates belts so im using qh

does anyone have a part number for qh of the belt i need

its the lawst bit thats need to finish the transplant

thanks

digita1dragon

get a piece of string round the pulleys, mark it where its as tight as it gets, then mark it again when its right open, then get the smallest belt possible in that range as they stratch after a few hundred miles

xr4x4rs

iTrader: (5)

tried that but failed mate

will try tomorrow now as im shattered and its my birthday lol

digita1dragon

well happy birthday

Moondust_crust

have you got any pics of your engine install mate so i can have a look for when i do mine, many thanx.

xr4x4rs

iTrader: (5)

not yet mate but will do soon

it looks a bit bodge in there at the minute as im mixing and matching things on the water sides so doesnt look pretty

just finished it all in the thunderstorms just now went to turn the key and it went pop and the cambelt snapped

so hopefully havnt done any damage will see tomorrow when i fit a cambelt

scort

I used a CVH fiesta alternator bracket,



Steve

xr4x4rs

iTrader: (5)

ive used the zetec one as it was there and finding a mk3 fiesta in a scrppy with that on is gona be a nitemare round here

the only problem im really confused on is the water system

i mean what do i use in rad terms and where do he pipes go and where they join to

like i say ive bodges it at the minute and have somehow managed to bodge a zetec rad in there but looks a mess and want it proper

any one shed some lite on the water side ofr me thanks explain what goes where

andre_k

iTrader: (2)

cam belt snapped??? unlucky m8! hope its ok...
was the zetec conv easy?

dre

xr4x4rs

iTrader: (5)

its fairly straight forward as long as your car is efi already

as mine is the efi mk4 there wasnt much of a problem

and the people so far who have helped carnt fault as its correct

Moondust_crust

hi mate tonyturbo reccomends using a mk4 rad as it will fit better in the slot provided, im not sure about the coolant pipe side of things though, just use whateva fits, trial and error, good luck with it all dude

xr4x4rs

iTrader: (5)

right having sum unlucky probs at the minute

done the cambelt and i was lucky nothing bent

just had all the exhaust done so i could fire it up and the alternators gon now

now when it was running i used the zetec ecu now it would missfire and overfuel

put the cvh ecu and it wouldnt tickover, but disconnected map sensor and ticksover

now the rev counter sticks at 2k and hardly moves?
and theres just pure fuel coming out of the exhaust

i swapped the two outer wires on the tps and that stopped the fuelling issue but then came a flat spot and 2k issue with the counter

do i need to use cvh coilpack instead of zetec to solve this

water issues im going to sort as i need to modify a rad to allow the header tank pipe in

any move advice from the gds who do zetec cus im buggered if i know

thanks

Kris Mainwaring

have to use efi cvh flywheel and rs turbo clutch in a mk4 zetec conversion....