Focus Zetec Into Mk4 Cabbie

[RobMk4TwinCarb]

Last year I bought a 2.0 zetec from a focus estate with 62k on the clock to put in the cabbie, I got a few bits and bobs last year and was just out in the shed stripping it down changing the flywheel etc and only just noticed it doesnt have a mount at the rear like older zetecs or the cvh but on the side.

 

This messed me up a bit until I done some reading and now I know where I am at roughly at least.

 

Now because it is the focus lump and not the mondeo do I have a need to change the sump and pick up pipe? It looks to me as though my current downpipe would run through the middle where the sump goes up.

 

I read on a site a guy has put one of these in a fiesta the same year as my cab, this engine mounts the starter and alternator on the rear of the block so I will have to use the parts for this engine, not a cvh alternator with the zetec pulley or a cvh starter. Does this mean I will be able to leave the water pump and oil pump in and not change them for escort zetec ones ? I dont even think the parts from the earlier zetecs fit so im hoping they will be ok.

 

So if what im thinking is right I dont need to change the sump, pick up pipe, water pump or oil pump and will just use the alternator and starter for this block.

 

I will also need to use the IB5 gearbox because of the rear mounting starter, I have seen pics with the same mounts as mine attached so it can be done, my only question on this is can it be any ib5 at all as they were in a fair few motors and will my cvh flywheel/clutch still be ok or would the focus ones work with it?

 

My main problem really is the side engine mount I have no problem making holes for it and doing it this way so long as I know I can actually fit it in, anyone know of anyone who put a series 3 zetec in any mk4 escort and has a clue whether it is pretty straight forward, ie make the holes in the right places or you need to be cutting and welding?

 

My last question is I was going to use a 1.8 escort zetec inlet with 2.0 mondeo injectors but after some reading this head takes different shaped pencil injectors or something, would the different injectors fit in the escort zetec manifold?(Im thinking not but doesnt hurt to ask) If not does anyone know whether the proper inlet for this engine would plug up at all? I dont mind doing some modifying but if all these things turn out to be stupidly complicated I will just sell this lump and use a series 2.

 

Anyone with any info would be greatly appreciated !

[gingergman]

you need to speak to gavintwopies he is the man for zetec, seems to be zetec hero, full of knowlege!!! hes usually on here in the evenings

[Guest gavintwopies]

This messed me up a bit until I done some reading and now I know where I am at roughly at least.

 

Now because it is the focus lump and not the mondeo do I have a need to change the sump and pick up pipe? It looks to me as though my current downpipe would run through the middle where the sump goes up.

 

 

Rite the black top engine you have will work as i have done one and there are a few differences to the silver top.

 

You don't need to swap the sump as you would have to do with a mondeo silver top however!!!!

 

If you wish to keep the front starter ib5 gearbox you will need to fit the silver top escort type sump as the starter will fould the black top sump, if you don't want to swap the sump you will need to fit a rear starter ib5 gearbox to get round this, the mk4 shafts will fit the later gearbox as will the selector.

 

 

I read on a site a guy has put one of these in a fiesta the same year as my cab, this engine mounts the starter and alternator on the rear of the block so I will have to use the parts for this engine, not a cvh alternator with the zetec pulley or a cvh starter. Does this mean I will be able to leave the water pump and oil pump in and not change them for escort zetec ones ? I dont even think the parts from the earlier zetecs fit so im hoping they will be ok.

 

you dont need to swap the oil pump on the blacktop as the main problem with the silvertop's is filter clearance problems as it screws on to the back of the oil pump where the black tops are like the cvh in that they screw direct to the back of the block so no clearance problems, the cvh alternator bracket will fit the front of the zetec block to keep it easier but the black top waterpump inlet/outlet will be a tight squeeze over the top of the alternator unless you use a fiesta underslung cvh alternator bracket this will give more room.

 

 

 

So if what im thinking is right I dont need to change the sump, pick up pipe, water pump or oil pump and will just use the alternator and starter for this block.

 

As above depending on how you intend on to get round the start clearance issue swap sump or swap gearbox??

 

 

 

I will also need to use the IB5 gearbox because of the rear mounting starter, I have seen pics with the same mounts as mine attached so it can be done, my only question on this is can it be any ib5 at all as they were in a fair few motors and will my cvh flywheel/clutch still be ok or would the focus ones work with it?

 

 

 

I know with regards to this you will need to use silvertop ib5 flywheel and use the mk4 escort clutch kit 1.6cvh,1.8diesel or rsturbo one or 1.6/1.8 zetec escort kit either.

 

 

 

My main problem really is the side engine mount I have no problem making holes for it and doing it this way so long as I know I can actually fit it in, anyone know of anyone who put a series 3 zetec in any mk4 escort and has a clue whether it is pretty straight forward, ie make the holes in the right places or you need to be cutting and welding?

 

 

Once the rear bracketry is removed from the blacktop behind the alternator there is the 3 holes found on the cvh the top nearest the innerwing is in the rite place the one under it is in the rite place i think? and the top one furthest away from the inner wing is about 10mm further away so slot the mk4 engine mount and this should be fine

 

 

My last question is I was going to use a 1.8 escort zetec inlet with 2.0 mondeo injectors but after some reading this head takes different shaped pencil injectors or something, would the different injectors fit in the escort zetec manifold?(Im thinking not but doesnt hurt to ask) If not does anyone know whether the proper inlet for this engine would plug up at all? I dont mind doing some modifying but if all these things turn out to be stupidly complicated I will just sell this lump and use a series 2.

 

Anyone with any info would be greatly appreciated !

 

Your best bet is to use a set of earlier 2.0 zetec injectors in the 1.8 zetec inlet as they are a direct replacement as like you say they are the later pencil one's that people tend to use in the cvh efi inlets when using an inlet adaptor plate and trying to run a zetec on cvh managment........ so sell them on to someone else who is trying to do it this way

 

hope this helps???

Edited May 7, 2011 by gavintwopies

[RobMk4TwinCarb]

You are a messiah!

 

Thanks alot for that it does help alot.

 

Since I posted I decided to try and sell this engine I have to help pay for the brake upgrade I need to finish as the mot is coming up and the rear really needed changing last year. I was going to go for a silvertop when I bought another one but I might get another one of these now..im actually tempted not to sell it at all

 

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=120722987044&ssPageName=STRK:MESELX:IT if anyone is interested!

[Guest AstonB]

For the record, i'm fitting blacktop from a mondeo into a mk4, but im keeping the rear starter and alternator, and also using ITB's.

 

I converted my inner wing to accept the side mount of the blacktop, not realising that this is also pretty much identical to later duratec mounts too. IB5 came from a later fiesta, my advise is to fit a later fiesta or ka gear linkage as its nice and short and new feeling, needs two holes drilling a bit further back than original though.

 

Word of advise, if you're keeping the aux setup exactly as it was on donor car, then you WILL need to modify chassis leg slightly, i've had to remove the brake bias adjuster mount and trim a small amount lower down too as the aux belt fouls these. I have a few pics so far if anyone is interested.