Zetec Install

Installing the Zetec

Obviously this is going to be completely mk3/4 Escort specific.

Engine ready to recieve the gearbox

Lining up the spline in the primary/input shaft with the clutch plate.

Gearbox mounted (or at least it will be once all the bolts are in).

Engine fitted from below as per the original engine, hence leaving the head off to improve clearance.

Slid into position.

Car lowered over it.

Engine and transmission assembly raised on scissor jacks. Gearbox mounts fitted (cross member in the case of mk4 Escorts).

Engine block mount fitted.
Ignore the rusty oil filter thread, this was later removed and a new portion fitted.

Oil filter pre-filled and fitted. The rigid brake pipes in the background may need a little massaging to improve clearance (to allow for engine movement).

Basic assembly mounted in place. All jacks supporting the engine removed.

Checking accuracy of TDC mark on the crank pulley. It was spot-on.

Head Gasket

Head fitted and torqued down.

Cam Timing Tools

Cams locked in timing position.

Cam timing set.

Crankcase breather system oil separator, exhaust manifold and heat shield fitted.

Thermostat housing and coil pack fitted.

Rocker cover and cambelt covers fitted.

Cooling System

Bottom Hose

Original plumbing from Mondeo mk2 donor car.

Dismantled into it's component parts so that the pipes angles can be adjusted to suite its new application.

'S' pipe length trimmed.

Re-assembled but no clips fitted yet until final assemble in the car to allow for repositioning.

This connects the water pump to the radiator bottom hose connection stepping neatly over the alternator.

The 'T' pipe from the bottom hose connects to a plastic water rail...

that runs along the top of the radiator.

This also comes from a Focus.

The connection is too small a diameter so in intermediate diameter hose was squeezed over it with sealant.

The two connections at the other end connect to the thermostat housing and the long heater return pipe from the bulkhead fitting.

Top Hose

Mondeo top hose with built in Coolant Temperature Sensor.

Length at radiator connection trimmed back.

Fitted.

Induction System

As mentioned in the parts swap section, a 2.0ltr Focus mk1 inlet manifold has been used.

Focus mk1 inlet manifold connections.

Fitted with good clearance.

I

Fuel rail with injectors.

Fitted.

Shiny new 2.0ltr Focus mk1 throttle body.

The Throttle Position Sensor (TPS) doesn't match the plug on the engines loom...

But the TPS sensors do send the same signal so...

A suitable plug is simply spliced into the loom in place of the original.

Fitted.

The accelerator cable bracket requires some modification to move it a bit further away from the throttle lever on the throttle body. Otherwise the throttle won't close any more than half way.

Top pipe - Focus mk1 leading to the original XR3i pipe.
Bottom pipe - later Escort Zetec.

Airflow meter mounts in the same space originally occupied by the Bosch K-Jet metering head when using the Focus/XR3i induction piping as I have.

Universal cone filter in a plastic flowerpot cold air induction kit, part of our 'Horticultural Horsepower' range.

Airflow meter mounted to it.

Final part of the induction pipework is from...

A hole was carefully cut into this section to accept the Inlet Air Temperature probe.

The system complete.

Exhaust System

The Escort Zetec downpipe is used and mated to the original exhaust system at the standard join (though in this case an aftermarket Janspeed but the join is still in the same place.)

The standard Escort downpipe has a small catalytic converter that had already been cut from my pipe. It would probably have to be removed anyway as it would have made the pipe too long to mate up with the rest of the standard exhaust.

A local exhaust specialist provided a length of pipe of the same diameter that they flared on one end and also a matching flange to bot up to the existing pipe. This was welded onto the end of the Escort Zetec downpipe. Note the lambda sensor.

Lined up ready for bolting together.

Complete.

Mobirise

The contents of this website are purely a reflection of my own experiences and knowledge gained whilst working on my various projects. Anything you do based on what you have read here is done so entirely at your own risk.
Personally I wouldn't trust someone like me with a lawn mower! You have been warned! Flapper-bat!

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