ka zetec project
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20-05-2012, 11:34 PM
#82
1.8 zetec ka in the makin
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top thinking mate ive got a couple old plates knocking about lol
mines basically the same but i removed the left middle vent for the temp gauge to be housed and the right one for the rev counter just gotta find sum plastic to fit the hole but as above number plate will work a treat lol
what did you use to fit the plastic in place ? tiger seal ??
mines basically the same but i removed the left middle vent for the temp gauge to be housed and the right one for the rev counter just gotta find sum plastic to fit the hole but as above number plate will work a treat lol
what did you use to fit the plastic in place ? tiger seal ??
26-05-2012, 01:56 PM
#84
1.8 zetec ka in the makin
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sorted cheers for that mate wil get it done and finished in the next week or so and get a picture of it up , aint worked on it for over a week now as im stupidly busy at the minute , but ive got the gauges in and working with all the wiring done just gotta get the mounting done ,tidy up the wires and start cooling system .
also got my hands on some puma 1.7 calipers , just need to get a disc and pad kit and some 14 inch or 15 inch alloys for them to fit behind then ill be able to start on the body work !!
also got my hands on some puma 1.7 calipers , just need to get a disc and pad kit and some 14 inch or 15 inch alloys for them to fit behind then ill be able to start on the body work !!
04-06-2012, 04:35 PM
#86
1.8 zetec ka in the makin
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im doing the body work and painting myself ,ive resprayed bikes and bits of cars previously so im not a rookie lol
im playing with the idea of fitting a fiesta zetec s rear beam and drum set up at the min but will see when i get to it .
anyway
got the water temp and revcounter mounted in the dash now
pcs are crap as per usual but u get the idea lol
im playing with the idea of fitting a fiesta zetec s rear beam and drum set up at the min but will see when i get to it .
anyway
got the water temp and revcounter mounted in the dash now
pcs are crap as per usual but u get the idea lol
06-06-2012, 08:33 AM
#92
1.8 zetec ka in the makin
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yes mate , i removed as much of the pipe work as i could and then blocked it up at the back of the dash.
ive used carpet on the plastic i had to cut and stick in and its turned out alot better than expected lol
shame my cameras crap !!
ive also made the air intake pipe to k and n air filter but need to get a picture of it and ive refitted the bonnet with raisers to help with cooling
ill keep this updated as and when i do more on it
ive used carpet on the plastic i had to cut and stick in and its turned out alot better than expected lol
shame my cameras crap !!
ive also made the air intake pipe to k and n air filter but need to get a picture of it and ive refitted the bonnet with raisers to help with cooling
ill keep this updated as and when i do more on it
Last edited by CR41G_86; 06-06-2012 at 08:35 AM.
07-07-2012, 02:56 PM
#94
1.8 zetec ka in the makin
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only update is that ive got 1 of the fuel lines properly connected up now still got to do the other 1 as its bigger and doesnt fit in the ka fuel line connector.
boot has been sanded back to bare metal and put in primer
aint had much time just latly with other commitments but hopefully will get on it asap , personally a good weekends work and whats left to do would be done its just finding the time
but i will keep updating as and when it happens
boot has been sanded back to bare metal and put in primer
aint had much time just latly with other commitments but hopefully will get on it asap , personally a good weekends work and whats left to do would be done its just finding the time
but i will keep updating as and when it happens
14-07-2012, 11:21 AM
#95
1.8 zetec ka in the makin
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update
both fuel lines are now connected up properly - total ball ache having to change connectors but its done now
all the loom in the engine bay is now done and covered with loom covers
all the air induction system is complete consisting of rs1800 over the block air pipe , ka rubber induction pipe , ka air flow sensor housing with rs1800 air flow meter installed , silicone hose coupler and k and n air filter
coolant tank now reinstalled and ive started to fit the coolant hoses
pictures will be uploaded at end of play tonight
both fuel lines are now connected up properly - total ball ache having to change connectors but its done now
all the loom in the engine bay is now done and covered with loom covers
all the air induction system is complete consisting of rs1800 over the block air pipe , ka rubber induction pipe , ka air flow sensor housing with rs1800 air flow meter installed , silicone hose coupler and k and n air filter
coolant tank now reinstalled and ive started to fit the coolant hoses
pictures will be uploaded at end of play tonight
Can't wait
15-07-2012, 10:28 AM
#97
1.8 zetec ka in the makin
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here we go a few pics ive just taken
first 2 pics are of the engine how it stands now , the 3rd pic is a descent pic of the gauges in the central vents and the 4th pic is after the boot had been primered and flatted back down.
ive started fitting the coolant pipe work ,
ive fitted ;- from bottle to thermostat , from heater matric to thermostat , and from thermostat to radiator incorperating a temperature sender housing for the temp gauge.
had a look at the mondeo bottom hose and its quite a simple fit just need a 45mm silicone coupler and 2 3 inch lengths of stainless steel 35mm id tube and the final 3 pipes are 16 mm id radiator house and simple fit once purchased, so yea hopefully get the cooling system finished by next week
first 2 pics are of the engine how it stands now , the 3rd pic is a descent pic of the gauges in the central vents and the 4th pic is after the boot had been primered and flatted back down.
ive started fitting the coolant pipe work ,
ive fitted ;- from bottle to thermostat , from heater matric to thermostat , and from thermostat to radiator incorperating a temperature sender housing for the temp gauge.
had a look at the mondeo bottom hose and its quite a simple fit just need a 45mm silicone coupler and 2 3 inch lengths of stainless steel 35mm id tube and the final 3 pipes are 16 mm id radiator house and simple fit once purchased, so yea hopefully get the cooling system finished by next week
15-07-2012, 10:33 AM
#98
1.8 zetec ka in the makin
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and forgot to mention ive changed the oil cap to a mk 6 escort one as its cosmetically more pleasing and ive removed the origional dipstick because it stuck up to high and hit the bonnet when i tryed to shut it so ive also changed that from a mk6 escort
16-07-2012, 07:26 PM
#99
Too many posts.. I need a life!!
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22-07-2012, 11:20 AM
#101
1.8 zetec ka in the makin
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update
ive got the mondeo bottom rad hose installed had to use a mixture of silicone couplers ,stainless steel joiners and some 35mm id pipe, so water pump is now connected to the radiator via the mondeo bottom 5 way radiator hose.
ive got 5meters of 16mm 1.d pipe ordered and thats all i need to complete cooling system !!
just need a new cat and were cooking on gas !!
ive also trimmed more of the slam panel so now it looks much better than the last pic i posted , ive also refitted the ignition cowling and i fixed the rear window as it wouldnt open or close properly because the screws had pulled through the metal, ive removed the rear wiper motor ,scrapped or ebayed all the left over stuff i dont need .
so little near future list of things i need to do
buy and fit new cat
buy and fit fiesta zetec s race middle section of exhaust
fit custom backbox
buy engine coolant /antifreeze mix
fill and bleed coolant system
change spark plugs again
do an engine flush (using an engine oil addative)
change oil
change oil filter
change pollen filter
change fuel filter
most of this could be done in a weekend so not much left really ive still got the 1.7 puma brake upgrade to do but that will be done at a later date
also got the body work to do ,so yea im still aiming to have it on the road in early spring
ive got the mondeo bottom rad hose installed had to use a mixture of silicone couplers ,stainless steel joiners and some 35mm id pipe, so water pump is now connected to the radiator via the mondeo bottom 5 way radiator hose.
ive got 5meters of 16mm 1.d pipe ordered and thats all i need to complete cooling system !!
just need a new cat and were cooking on gas !!
ive also trimmed more of the slam panel so now it looks much better than the last pic i posted , ive also refitted the ignition cowling and i fixed the rear window as it wouldnt open or close properly because the screws had pulled through the metal, ive removed the rear wiper motor ,scrapped or ebayed all the left over stuff i dont need .
so little near future list of things i need to do
buy and fit new cat
buy and fit fiesta zetec s race middle section of exhaust
fit custom backbox
buy engine coolant /antifreeze mix
fill and bleed coolant system
change spark plugs again
do an engine flush (using an engine oil addative)
change oil
change oil filter
change pollen filter
change fuel filter
most of this could be done in a weekend so not much left really ive still got the 1.7 puma brake upgrade to do but that will be done at a later date
also got the body work to do ,so yea im still aiming to have it on the road in early spring
27-07-2012, 10:58 AM
#102
1.8 zetec ka in the makin
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update
colling system complete apart from a few jubaliee clips that i need to go and get
ive got a second hand cat on the way
once this is here im goin to throw together a make shift exhaust so i can flush the engine and fill and bleed the cooling system then its just basic servicing of new oil oil filter ,spark plugs etc and do some general tidying up
pictures will folow as and when i do sumet next lol
colling system complete apart from a few jubaliee clips that i need to go and get
ive got a second hand cat on the way
once this is here im goin to throw together a make shift exhaust so i can flush the engine and fill and bleed the cooling system then its just basic servicing of new oil oil filter ,spark plugs etc and do some general tidying up
pictures will folow as and when i do sumet next lol
20-08-2012, 09:33 PM
#103
1.8 zetec ka in the makin
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aint updated this for a while !!
ive since bought and fitted a new cat and gasket , and knocked up a makeshift exhaust from the old ka exhaust system .
ive filled and bled the coolant system , flushed the engine with wynns engine flush , replaced the oil filter , filled with new oil , new spark plugs ,new pollen filter , new fuel filter and new heater control valve.
it turns out it wasnt the heater control valve was the fault it was the heater control panel which i have a new one ready to be fitted ,
when scuttle was removed to change the pollen filter it was being held together with super glue ,tiger seal and cable ties so scrapped it and got another one from the scrap yard.
rev counter has been removed as it wasnt working correctly (apparently its for british leyland vehicles only) i have a new one on order that matches my temp gauge.
temp gauge temperature sender and housing had to be rotated around because the sender wires were to close to exhaust manifold and once it over heated it stoped sending the signal but after rotating its been fine.
front crossmember and slam panel and suspension turrets were cleaned back rust treated primered and painted matt black
i have bought a set of escort series 2 rs turbo alloys - great condition for age just need a lick of paint.
sit rep is - paint bonnet shut in matt black
fit new heater control panel
fit new rev counter when it arrives
buy puma 1.7 disc and pad kit
fit front brake upgrade and bleed the calipers
buy and fit fiesta zetec s exhaust system
ive since bought and fitted a new cat and gasket , and knocked up a makeshift exhaust from the old ka exhaust system .
ive filled and bled the coolant system , flushed the engine with wynns engine flush , replaced the oil filter , filled with new oil , new spark plugs ,new pollen filter , new fuel filter and new heater control valve.
it turns out it wasnt the heater control valve was the fault it was the heater control panel which i have a new one ready to be fitted ,
when scuttle was removed to change the pollen filter it was being held together with super glue ,tiger seal and cable ties so scrapped it and got another one from the scrap yard.
rev counter has been removed as it wasnt working correctly (apparently its for british leyland vehicles only) i have a new one on order that matches my temp gauge.
temp gauge temperature sender and housing had to be rotated around because the sender wires were to close to exhaust manifold and once it over heated it stoped sending the signal but after rotating its been fine.
front crossmember and slam panel and suspension turrets were cleaned back rust treated primered and painted matt black
i have bought a set of escort series 2 rs turbo alloys - great condition for age just need a lick of paint.
sit rep is - paint bonnet shut in matt black
fit new heater control panel
fit new rev counter when it arrives
buy puma 1.7 disc and pad kit
fit front brake upgrade and bleed the calipers
buy and fit fiesta zetec s exhaust system
23-08-2012, 10:42 AM
#104
1.8 zetec ka in the makin
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update
fitted new heater control panel ,still didnt cure the heater problem , found out i had to tap into the rev counter wire and connect it to the black/white wire on the back of the heater control panel an now its working perfectly.
bonnet shuts now painted matt black
refitted scuttle panel and wiper arms .
fitted new heater control panel ,still didnt cure the heater problem , found out i had to tap into the rev counter wire and connect it to the black/white wire on the back of the heater control panel an now its working perfectly.
bonnet shuts now painted matt black
refitted scuttle panel and wiper arms .
30-03-2014, 08:20 PM
#106
Wahay!! I've lost my Virginity!!
Hello mate I know this is fairly old now but I need to try, u wouldn't happen to have the auxiliary belt tensioner still would u? and consider selling it if u do? I am so desperate u wouldn't believe 
if u could PM me either way id really appreciate it, thanks
if u could PM me either way id really appreciate it, thanks
06-07-2017, 05:32 PM
#107
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08-07-2017, 12:56 PM
#108
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need a crank and cam locking kit to change the cam belt
1. remove cambelt, tensioner and water pump
2 fit new cambelt , tensioner and water pump
3. refit cam belt covers
4. refit crank pulley and water pump pulley
5. fit a cvh alternator bracket and refit alternator
6. fit new fan belt
7. refit rocker cover with new gasket
1. remove cambelt, tensioner and water pump
2 fit new cambelt , tensioner and water pump
3. refit cam belt covers
4. refit crank pulley and water pump pulley
5. fit a cvh alternator bracket and refit alternator
6. fit new fan belt
7. refit rocker cover with new gasket
Here's the tool: https://www.machinemart.co.uk/p/clar...g-locking-kit/
28-03-2018, 10:07 PM
#109
engine mount Zetec into KA
im currently under taking a ka zetec conversion , the car is a 1998 ka basemodel with no powersteering, air con etc , the engine is a ford escort xr3i 130 ps 1.8 16v zetec
i started off removing the front bumper and standard engine from the car
Attachment 140767
Attachment 140768
this is the rear gear box mount (with 3 t55 bolts holding it to the box)
Attachment 140769
gearbox front mount (3 bolts i think there 13mm)
Attachment 140770
and drivers side engine mount was 4 13mm bolts ,this is a pic of the standard ka mount removed showing the bolt holes used for the custom mount
Attachment 140771
when the engine arrived i took a picture of the fan belt showing origional set up
Attachment 140772
since this the alternator and bracket has been removed aswell as the idler wheel and fan belt tensioner and the powersteering pump and bracket , leaving the water pump and crank pullys.
im currently on the look out for a mk 2 fiesta xr2 alternator mount and adjustment bracket to be able to refit the alternator to the engine (this needs to be done because the standard alternator bracket makes the alt sticks out to far and will foul the front crossmember.
in the mean time ive removed the exhaust manifold and head sheild cleaned them up and painted them in heat resisitant silver
Attachment 140773
ive also started cleaning up the ka gear box as it was plastered in oil from the standard ka engine (whichh was really really sick when i bought it)
Attachment 140774
and ive also started cleaning up the inlet manifold
Attachment 140775
i then bought an rs turbo rubber mount and backing cup
Attachment 140776
the cup has to be modified to fit the engine i will post a picture of this shortly
this is the picture of the custom engine mount bracket that is needed , in this picture it is bolted the the rs turbo rubber mount
Attachment 140777
and again bolted into the car (still needs to come off and be painted as its only in primer at the min
Attachment 140778
ive also puchased an ecu just need an rs1800 /xr2i 16v wiring harness
aswell as the mk 2 xr2 alternator bracket and adjustment arm
next to do is remove rocker cover and prep and paint it and refit with new rocker gasket ,change the cam belt and once the alternator is fitted measure and fit new fan belt
so more to come
i started off removing the front bumper and standard engine from the car
Attachment 140767
Attachment 140768
this is the rear gear box mount (with 3 t55 bolts holding it to the box)
Attachment 140769
gearbox front mount (3 bolts i think there 13mm)
Attachment 140770
and drivers side engine mount was 4 13mm bolts ,this is a pic of the standard ka mount removed showing the bolt holes used for the custom mount
Attachment 140771
when the engine arrived i took a picture of the fan belt showing origional set up
Attachment 140772
since this the alternator and bracket has been removed aswell as the idler wheel and fan belt tensioner and the powersteering pump and bracket , leaving the water pump and crank pullys.
im currently on the look out for a mk 2 fiesta xr2 alternator mount and adjustment bracket to be able to refit the alternator to the engine (this needs to be done because the standard alternator bracket makes the alt sticks out to far and will foul the front crossmember.
in the mean time ive removed the exhaust manifold and head sheild cleaned them up and painted them in heat resisitant silver
Attachment 140773
ive also started cleaning up the ka gear box as it was plastered in oil from the standard ka engine (whichh was really really sick when i bought it)
Attachment 140774
and ive also started cleaning up the inlet manifold
Attachment 140775
i then bought an rs turbo rubber mount and backing cup
Attachment 140776
the cup has to be modified to fit the engine i will post a picture of this shortly
this is the picture of the custom engine mount bracket that is needed , in this picture it is bolted the the rs turbo rubber mount
Attachment 140777
and again bolted into the car (still needs to come off and be painted as its only in primer at the min
Attachment 140778
ive also puchased an ecu just need an rs1800 /xr2i 16v wiring harness
aswell as the mk 2 xr2 alternator bracket and adjustment arm
next to do is remove rocker cover and prep and paint it and refit with new rocker gasket ,change the cam belt and once the alternator is fitted measure and fit new fan belt
so more to come
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