UPDATED: GUIDE: Fitting our Blacktop Zetec 190bhp Package to a Mk3 1800 Fiesta
27-01-2010, 08:18 PM
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UPDATED: GUIDE: Fitting our Blacktop Zetec 190bhp Package to a Mk3 1800 Fiesta
Hi everyone,
Heres a lil project we are undertaking for a chap who is a driving tutor at Castle Combe.... upgrading his RS1800 Mk3 to run our Zetec 190 bhp engine
This will also form some sort of a guide I hope, so anything interesting I find I will post up
We have a customer who is after us fitting said engine to his Mk3 RS1800i Fiesta.
UPDATE 18/02/2010
Old and New...
After removing the old 1.8 silvertop engine, you can see it here side by side with the 2.0 Blacktop:
Fitting RS1800 Sump
We carried out the spacer mod on the windage tray as per GTI_Toms info (thanks!) and built the engine back up with the RS1800 sump. This is needed to be done as the mondeo exhaust system (and hence sump shape) is different from the Fiesta.
For reference, the spacers are fitted between the bolt head and bearing cap. Height = 19mm, OD = 21mm, ID = 13mm. If anyone needs some we can turn them up....
You will also need to fit the Fiesta pickup pipe, but thats a straight swap. Just use a new gasket...
Flywheel
You must use the RS1800 flywheel, rather than the mondeo clutch, I believe that it is the same as any silvertop 1800 flywheel....
We then removed the standard mondeo 2.0 flywheel and fitted the one from the RS1800. (Remember to use new bolts as they are the stretch type!) Also, fit the CPS from the 1.8 as it is a different length to read the flywheel correctly. We then fitted an uprated RS1800 clutch kit.
The SuperSport Kent FOCUS3 Cams were then fitted to the head, and a new cambelt kit installed. (We are a Kent dealer, so drop us a line if you're after some...)
Running the Water Pump and Alternator
We used an idler pulley and bracket from RetroFord, (under £40 for the whole kit) which means we can run the serpentine mondeo water pump correctly.
Russ (our smelly yet able mechanic) then cut the original alternator/front mount down such that the standard RS1800 alty could be fitted without the front engine mount which normally would foul the Mondeo 2.0 water pump.
Rear (cam pulley end) Engine Mount
After getting our hands on modified rear engine mount (thanks to Si at Si-Tech Racing) we then refitted the engine to the bay. Its an RS Turbo item modifited to fit the blacktop bolt pattern.
Cooling System
Tony won't be running heaters, which means we could simply connect our water pump outlet straight up to the rad. If you are going to be running a heater matric, you will need a T-Piece to feed the matrix. The thermostat outputs for the heater matrix can be simply looped around.
The thermostat housing is removed from the silvertop and fitted to the blacktop engine to retain the factory sensors....
Throttle Bodies
The next step was drilling and tapping the Jenvey inlet manifold to allow fitment of a brake vacuum takeoff for the servo.
More pics/info to come....
Heres a lil project we are undertaking for a chap who is a driving tutor at Castle Combe.... upgrading his RS1800 Mk3 to run our Zetec 190 bhp engine
This will also form some sort of a guide I hope, so anything interesting I find I will post up
We have a customer who is after us fitting said engine to his Mk3 RS1800i Fiesta.
UPDATE 18/02/2010
Old and New...
After removing the old 1.8 silvertop engine, you can see it here side by side with the 2.0 Blacktop:
Fitting RS1800 Sump
We carried out the spacer mod on the windage tray as per GTI_Toms info (thanks!) and built the engine back up with the RS1800 sump. This is needed to be done as the mondeo exhaust system (and hence sump shape) is different from the Fiesta.
For reference, the spacers are fitted between the bolt head and bearing cap. Height = 19mm, OD = 21mm, ID = 13mm. If anyone needs some we can turn them up....
You will also need to fit the Fiesta pickup pipe, but thats a straight swap. Just use a new gasket...
Flywheel
You must use the RS1800 flywheel, rather than the mondeo clutch, I believe that it is the same as any silvertop 1800 flywheel....
We then removed the standard mondeo 2.0 flywheel and fitted the one from the RS1800. (Remember to use new bolts as they are the stretch type!) Also, fit the CPS from the 1.8 as it is a different length to read the flywheel correctly. We then fitted an uprated RS1800 clutch kit.
The SuperSport Kent FOCUS3 Cams were then fitted to the head, and a new cambelt kit installed. (We are a Kent dealer, so drop us a line if you're after some...)
Running the Water Pump and Alternator
We used an idler pulley and bracket from RetroFord, (under £40 for the whole kit) which means we can run the serpentine mondeo water pump correctly.
Russ (our smelly yet able mechanic) then cut the original alternator/front mount down such that the standard RS1800 alty could be fitted without the front engine mount which normally would foul the Mondeo 2.0 water pump.
Rear (cam pulley end) Engine Mount
After getting our hands on modified rear engine mount (thanks to Si at Si-Tech Racing) we then refitted the engine to the bay. Its an RS Turbo item modifited to fit the blacktop bolt pattern.
Cooling System
Tony won't be running heaters, which means we could simply connect our water pump outlet straight up to the rad. If you are going to be running a heater matric, you will need a T-Piece to feed the matrix. The thermostat outputs for the heater matrix can be simply looped around.
The thermostat housing is removed from the silvertop and fitted to the blacktop engine to retain the factory sensors....
Throttle Bodies
The next step was drilling and tapping the Jenvey inlet manifold to allow fitment of a brake vacuum takeoff for the servo.
More pics/info to come....
Last edited by M-Tech Automotive; 18-02-2010 at 05:58 PM.
27-01-2010, 08:43 PM
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you need to do the following:
mod engine mount
get a front mount alternator kit from trackdesign's (this also make's the water pump spin the right way)
mod the sump to allow the started and o/f drive shaft to fit (im using a rs2k mtx75 box so might be different for a festa box?)
mod exhaust to suit lower sump
that's about it i think.
if you check my mk5 turbo thread i have picture's of a couple of the problem's
you should be able to use all the inlet and exhaust manifold's, management etc from the car, unless you wanted aftermarket gear?
mod engine mount
get a front mount alternator kit from trackdesign's (this also make's the water pump spin the right way)
mod the sump to allow the started and o/f drive shaft to fit (im using a rs2k mtx75 box so might be different for a festa box?)
mod exhaust to suit lower sump
that's about it i think.
if you check my mk5 turbo thread i have picture's of a couple of the problem's
you should be able to use all the inlet and exhaust manifold's, management etc from the car, unless you wanted aftermarket gear?
27-01-2010, 08:45 PM
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you don't need to change the sump etc. just fit the 220mm flywheel, the mount has one or two holes different but you can use the standard one if you modify it for the holes. The water pump rotates in the opposite direction so all is needed is to put an extra idler pulley in place and chop the alternator bracket
28-01-2010, 05:03 PM
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All the blacktop sumps I've used are the right shape but if its not then just swap the 1.8 sump over. I'm led to believe the blacktop in the mondeo had a different sump.
This blacktop sump is ok
If you fit the silvertop sump you can still keep the windage tray
you need to swap 4 of the main bearing cap bolts to silvertop ones and fit some spacers between the bolt head and bearing cap. Height = 19mm, OD = 21mm, ID = 13mm
This blacktop sump is ok
If you fit the silvertop sump you can still keep the windage tray
you need to swap 4 of the main bearing cap bolts to silvertop ones and fit some spacers between the bolt head and bearing cap. Height = 19mm, OD = 21mm, ID = 13mm
04-07-2013, 09:45 AM
#5
I dont surppose anyone would have a part number for the silver top windage tray bolt at all? Been to fords and orderd the right bolt but it came through as the one without the extra stud on grrrr
I nees some spacers made up too Matt, if thats something you could help with?
I nees some spacers made up too Matt, if thats something you could help with?
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11-02-2017, 08:28 PM
#8
I've found that life I needed.. It's HERE!!
Same ways as any engine. Make it breath.
Keeping the 1.8 silvertop Zetec ,
Carbs or throttle bodies with standalone ecu. 150bhp then it's port the head, cams and throttle bodies with standalone ecu and up the engine to 2.0, will go to around 200bhp.
St170 lump. Vvt Delete throttle bodies with stand alone ecu will go to around 200bhp.
Good exhaust.
Turbo Zetec on standard internals 200~250
Turbo Zetec/St170 hybrid 300+
Turbo Zetec with forged bottom end. Power is only limited by your wallet lol.
Keeping the 1.8 silvertop Zetec ,
Carbs or throttle bodies with standalone ecu. 150bhp then it's port the head, cams and throttle bodies with standalone ecu and up the engine to 2.0, will go to around 200bhp.
St170 lump. Vvt Delete throttle bodies with stand alone ecu will go to around 200bhp.
Good exhaust.
Turbo Zetec on standard internals 200~250
Turbo Zetec/St170 hybrid 300+
Turbo Zetec with forged bottom end. Power is only limited by your wallet lol.
Last edited by big_wasa; 11-02-2017 at 08:35 PM.
13-02-2017, 01:21 PM
#10
I've found that life I needed.. It's HERE!!
Nothing from the dohc is a bolt on fit to a zetec. The st170 exhaust manifold is a cheap upgrade if it will work with your sump.
Stand alone engine management systems are available in lots of flavours. Google Mega squirt, Omex, Dta but more important than brand is finding some one near you that can map it.
When you look at the price of the ecu you need to budget on double again for a wiring loom and mapping if you can not do it your self.
Stand alone engine management systems are available in lots of flavours. Google Mega squirt, Omex, Dta but more important than brand is finding some one near you that can map it.
When you look at the price of the ecu you need to budget on double again for a wiring loom and mapping if you can not do it your self.
27-04-2017, 06:03 PM
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Alternator bracket
i know this is an old post but i was wondering if the alternator bracket has been spaced out at all, as the tensioner seems to foul the waterpump, any pics or advice would be grately appeciated, plus the spacers for the windage tray would b needed, where could i get some and a rough price if possible, thanks
Hi everyone,
Heres a lil project we are undertaking for a chap who is a driving tutor at Castle Combe.... upgrading his RS1800 Mk3 to run our Zetec 190 bhp engine
This will also form some sort of a guide I hope, so anything interesting I find I will post up
We have a customer who is after us fitting said engine to his Mk3 RS1800i Fiesta.
UPDATE 18/02/2010
Old and New...
After removing the old 1.8 silvertop engine, you can see it here side by side with the 2.0 Blacktop:
Fitting RS1800 Sump
We carried out the spacer mod on the windage tray as per GTI_Toms info (thanks!) and built the engine back up with the RS1800 sump. This is needed to be done as the mondeo exhaust system (and hence sump shape) is different from the Fiesta.
For reference, the spacers are fitted between the bolt head and bearing cap. Height = 19mm, OD = 21mm, ID = 13mm. If anyone needs some we can turn them up....
You will also need to fit the Fiesta pickup pipe, but thats a straight swap. Just use a new gasket...
Flywheel
You must use the RS1800 flywheel, rather than the mondeo clutch, I believe that it is the same as any silvertop 1800 flywheel....
We then removed the standard mondeo 2.0 flywheel and fitted the one from the RS1800. (Remember to use new bolts as they are the stretch type!) Also, fit the CPS from the 1.8 as it is a different length to read the flywheel correctly. We then fitted an uprated RS1800 clutch kit.
The SuperSport Kent FOCUS3 Cams were then fitted to the head, and a new cambelt kit installed. (We are a Kent dealer, so drop us a line if you're after some...)
Running the Water Pump and Alternator
We used an idler pulley and bracket from RetroFord, (under £40 for the whole kit) which means we can run the serpentine mondeo water pump correctly.
Russ (our smelly yet able mechanic) then cut the original alternator/front mount down such that the standard RS1800 alty could be fitted without the front engine mount which normally would foul the Mondeo 2.0 water pump.
Rear (cam pulley end) Engine Mount
After getting our hands on modified rear engine mount (thanks to Si at Si-Tech Racing) we then refitted the engine to the bay. Its an RS Turbo item modifited to fit the blacktop bolt pattern.
Cooling System
Tony won't be running heaters, which means we could simply connect our water pump outlet straight up to the rad. If you are going to be running a heater matric, you will need a T-Piece to feed the matrix. The thermostat outputs for the heater matrix can be simply looped around.
The thermostat housing is removed from the silvertop and fitted to the blacktop engine to retain the factory sensors....
Throttle Bodies
The next step was drilling and tapping the Jenvey inlet manifold to allow fitment of a brake vacuum takeoff for the servo.
More pics/info to come....
Heres a lil project we are undertaking for a chap who is a driving tutor at Castle Combe.... upgrading his RS1800 Mk3 to run our Zetec 190 bhp engine
This will also form some sort of a guide I hope, so anything interesting I find I will post up
We have a customer who is after us fitting said engine to his Mk3 RS1800i Fiesta.
UPDATE 18/02/2010
Old and New...
After removing the old 1.8 silvertop engine, you can see it here side by side with the 2.0 Blacktop:
Fitting RS1800 Sump
We carried out the spacer mod on the windage tray as per GTI_Toms info (thanks!) and built the engine back up with the RS1800 sump. This is needed to be done as the mondeo exhaust system (and hence sump shape) is different from the Fiesta.
For reference, the spacers are fitted between the bolt head and bearing cap. Height = 19mm, OD = 21mm, ID = 13mm. If anyone needs some we can turn them up....
You will also need to fit the Fiesta pickup pipe, but thats a straight swap. Just use a new gasket...
Flywheel
You must use the RS1800 flywheel, rather than the mondeo clutch, I believe that it is the same as any silvertop 1800 flywheel....
We then removed the standard mondeo 2.0 flywheel and fitted the one from the RS1800. (Remember to use new bolts as they are the stretch type!) Also, fit the CPS from the 1.8 as it is a different length to read the flywheel correctly. We then fitted an uprated RS1800 clutch kit.
The SuperSport Kent FOCUS3 Cams were then fitted to the head, and a new cambelt kit installed. (We are a Kent dealer, so drop us a line if you're after some...)
Running the Water Pump and Alternator
We used an idler pulley and bracket from RetroFord, (under £40 for the whole kit) which means we can run the serpentine mondeo water pump correctly.
Russ (our smelly yet able mechanic) then cut the original alternator/front mount down such that the standard RS1800 alty could be fitted without the front engine mount which normally would foul the Mondeo 2.0 water pump.
Rear (cam pulley end) Engine Mount
After getting our hands on modified rear engine mount (thanks to Si at Si-Tech Racing) we then refitted the engine to the bay. Its an RS Turbo item modifited to fit the blacktop bolt pattern.
Cooling System
Tony won't be running heaters, which means we could simply connect our water pump outlet straight up to the rad. If you are going to be running a heater matric, you will need a T-Piece to feed the matrix. The thermostat outputs for the heater matrix can be simply looped around.
The thermostat housing is removed from the silvertop and fitted to the blacktop engine to retain the factory sensors....
Throttle Bodies
The next step was drilling and tapping the Jenvey inlet manifold to allow fitment of a brake vacuum takeoff for the servo.
More pics/info to come....
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