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PostPosted: Sun Oct 24, 2004 6:25 pm 
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Can one of you mods move this to the FAQ section please, still under my name if pos :mrgreen: Cheers


Ok, here's a basic overview of how to fit a 2ltr Zetec into a mk2 Fiesta.

When we done this conversion, we followed Jim Hearnes all the way, as it pretty much explains very well how to do it.

I've done this guide though just to clear up or make certain things easier, as Jim's guide does have a few flaws, and certain things we couldn't quite understand etc. These are just things we found and problems we met and overcome whilst we did this conversion.

I hope a combination of this and Jim's guide will help you on your way to 16v happiness.

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I'll go through these tips in the same order as Jim's site, so best open that page in another window, and flick between the two.


Engine Mount:

His is pretty much spot on, though bear in mind you do not really need the 4th hole, as 3 will suffice, unless you are planning big power!

At this point I wish I took photographs of the stages of mine, but alas I forgot! Suffice to say, it isn't as hard as it seems if you can weld/ know someone who can. My mount is simpler than Jim's, in that after I cut the lip off the bottom left mount, and cleaned it up, I cut a piece of stainless to fit in the curve area. I then got that welded on, then cut another piece that fits over the top to strengthen it. Line it up with the block, and mark out the holes.

This photo shows the ally plate I made up to bolt the mount to whilst it was welded, so it all lined up exactly
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This is the mount already fitted to the engine, you can see the extension added
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Oil filter:

As per Jim's site.


Alternator:

As per Jim's site. I will point out, when buying a new alt belt, buy one for a 16/1800 Escort/ Fiesta, as I'm not too sure if the Mondeo one is a different size.


Wiring:

The real headache for some people, myself included! My friend did all the wiring for me in my car, so I can't be of direct help here, but what I will say is all he did was arm himself with a printout of Jim's diagram and a Mondeo Haynes manual, and worked it all out from there. Note: Do Not use a Fiesta or Escort Zetec Haynes manual, as the wiring is completely different!. We found that out the hard way!

At the end of the day, the really is only 4 wires you need to wiring into the existing loom; Earth, Power, ignition live and rev counter. Then rest of the wiring is self contained to the engine injection loom, and direct from the ECU, such as the fuel pump, etc.

When it comes to the ECU, make sure you get the correct one. There are several ECU's out there, but the main three that used are DEEP, DEWY and DESK. These names refer to what is printed on the ECU stickers. I'm pretty sure that all 2ltr ECU's start with the letter 'D', so if yours doesn't, then chances are it isn't a 2ltr one. Note: Do Not use an ECU from an automatic as it will not run correct. DEEP is often referred to as the best choice.

Visit the fiestaturbo.com forums and run a search here for more information on them.

(Note: I'm not sure about 1600/ 1800 ECU set ups, although chances are you'll be doing a 2ltr conversion anyway ;) )


Petrol Tank:

As Jim's guide. Although at the end of the day, it will be exactly the same as doing any injection conversion, RST etc, so search for various guides how to make them if you need further help.


Fuel Pump:

See above.


Fuel Plumbing:

You can use the standard XR fuel lines, though you need to change the end connectors.


Inlet Manifold:

As per Jim's guide. If you are using a 16/1800 inlet, you'll clearly see what Jim was on about with it fouling the mount, and is easy to mod with a grinder when off the engine.

Here you can just make out where the mount hits the inlet and needs grinding.
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You cannot use Mondeo inlets as they are too big.

The plastic Focus inlets apparently fit, although I have not tried this myself, though I will do.

The downsides to using the ally Escort/ Fiesta inlets is that they don't flow the air as well as the Mondeo or Focus ones do if you're running a 2ltr. I don't think it is noticeable, and many mk3 Fiesta owners that do this conversion have never had problems. Just thought I'd note it though.


Air Filter, Battery, Accelerator Cable:

As per Jim's site. Note, if using an aftermarket cone filter, you do not need to move the battery.


Radiator fan switch:

Use the top radiator hose from a Zetec Escort (maybe fiesta) as this already has the mount it. Fit your XR switch.

I got mine from a mk5 XR3I
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Jim's guide then goes through the various bits you will need for this conversion, all are pretty much correct, except for..

Flywheel and clutch:

You can use a 16/1800 Zetec flywheel no problems, but you can also use a EFi CVH flywheel too. I used an XR2I flywheel, although you have to open the bolts up slightly. I forgot the exact measurement, but 1mm will be fine.

Also, its worth pointing out that a CVH flywheel is lighter than a Zetec one, so using a CVH will in effect give you a 'Lightened Flywheel' ;)

Make sure you use the correct CPS (crank position sensor) with the flywheel, otherwise it wont want to know. Don't use a 2ltr one, because of the position it sits in. The 2ltr one aims further out, so it misses the timing marks on the 16/1800 or CVH flywheel, therefore wont start.


You can use any CVH clutch, so choose at will. I would suggest at least an RST item, as they are rated for 130bhp as standard, which is the same as the 2ltr.


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Ok, so that's my 'Update' of Jim's guide over with. Here are some other things that he forgot and are often asked about when it comes to this conversion


Gearbox:

The XR2 gearbox is perfectly fine to use. It handles the power pretty well, and is good for acceleration.

But go ahead an treat yourself to a nice S1or S2 RST gearbox with a nice LSD ;) Will be handy when its wet, trust me :lol:


Exhaust:

You can use a standard XR system or anything that designed for a XR2 up to the downpipe. For here you'll have to get creative to mate them up, but its not too hard, esp. if you can weld.

Bear in mind, our cars were made in the 80's, so we don't need a catalytic converter to pass an MOT ;)

Use a 16/1800 Zetec Manifold and downpipe for ease.

If you have a CVH 4 branch manifold, note that the ports line up fine, but none of the bolt holes do, so you will have to get creative here as well if you want to fit it.


Other things to mention would be the bottom Radiator hose, you will have to use a XR one, but will need to mod it as its too long to marry up. I cut mine in half, trimmed to the length needed, then used a piece of stainless tube inserted in the middle and jubilee clipped it tight. Forcing the hose onto the zetec water is tricky, but can be done.

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For the starter motor, you can use any fwd CVH item. Also a diesel starter will do the trick also. I'm pretty sure that you can use a Zetec starter from a Fiesta or Escort, but I can't confirm this. I personally am using a starter from a CVH automatic, and seems to work perfectly.

Its very important to make sure you have the right sensors for the correct cc of your engine. For example, if you're doing the 2ltr conversion, and have collected 1800 parts for it to fit, remember to swap them over, e.g. the MAF sensor, idle speed control valve etc, otherwise it'll run erratically.

You can fit a 2ltr throttle body to the 16/1800 inlet, although you will need to use the linkages from the 16/1800 throttle body, and mod the arms, as they are thicker, but its easy to see once you get them side by side and taken apart.

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Whilst you've got the engine out, you may want to think about up-rating the rubber mounts with poly ones instead ;)

Throttle body conversions, Twin 40's etc may have a few variations in set-up, mainly in wiring and management. Go to zetecinside.com for further information on this. Also the fiestaturbo.com forums are a good place to go and search, as there is a lot of info to be found there :)

If you're doing a ZVH conversion, you can take in account anything I have mentioned about the bottom end, as it's the same.


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If I think of anymore information or extra things to add, then I will get of the mods to update this for me. If you get stuck or need any help, then just ask me or post up a question on the board, as a lot of people know what they're talking about, and know alot more than me! :lol:

I'd also like to once again thank Rich, aka 'Rolls' and Rob, aka 'mk2xr2', for helping me out alot when I was doing this conversion, more so Rich who persisted through many phonecalls, txt messages and huge essays pm'd to him! :lol: Cheers guys ;)


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Last edited by Ben on Sun Oct 24, 2004 7:03 pm, edited 1 time in total.

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PostPosted: Sun Oct 24, 2004 6:55 pm 
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Cool, i have a question though, why should you not use a 2.0 CPS?

P.S.. You ganna get it chipped? :twisted:


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PostPosted: Sun Oct 24, 2004 6:59 pm 
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Good job Number 1! 8)

Also...liking your adaption of the Jim Hearne engine mount...seems a MUCH easier way to do it. Though, I wonder why Jim Himself didnt do that?! He loves his tinkering does he!

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PostPosted: Sun Oct 24, 2004 7:01 pm 
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Because of the position it sits in. The 2ltr one aims further out, so it misses the timing marks on the 16/1800 or CVH flywheel, therefore wont start.

This is one of the problems we didn't notice when we was trying to get it started... meaning my engine was never a 'runner' as was said to me! lol

I best add that bit in then ;)


Chipped... maybe, not yet. Got a few other things i want to get done first, mainly bodywise before i spend on the engine. Oh, and uprate the brakes ;)

2/3, i dunno why, maybe he was just trying to make it look more 'professional', i dunno? I did mine like that as we just had some odd bits of stainless steel lying about that was the same thickness as the mounts steel.

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