Exchange 1.6 1.8 2.0 Zetec Engines
DOHC 16 VALVE DIRECTORY AND PRICES
Description Price
01 Standard Reconditioned Engine £ 871.00
04 Modified Stage 3 £ 1654.00
(Not suitable for standard injection)
ZETEC SPECIFICATION
EXCHANGE 1.6 / 1.8 / 2.0 ENGINES
Our standard and modified engines will directly replace any of the Ford based Zeta double overhead cam models such as Escorts, Fiestas, Mondeos’, Morgans, Westfields, and many kit cars.
01 Standard Reconditioned Engines
All parts immersed in acid ‘bath’ then chemically ‘hot’ washed and cleaned, with all core and oil gallery plugs removed.
Cylinder Head
Completely reconditioned with new valve springs, valve guides, valve stem oil seals. All cylinder head surfaces are machined with the emphasis on the minimum amount removed. All valve seats re-cut or new inserts fitted as required. All valves are VAC tested to ensure optimum seating.
Cylinder Block
Rebored and crosshatch honed. All new core plugs fitted. New matched set of pistons. Mains checked for alignment and ovality and surfaces machined as necessary.
Crank Shaft
All crank shafts are linished or reground and polished and checked for straightness and crack tested. All new main bearings and big end bearings are fitted as standard.
Conrods
Check for alignment and ovality in big end housings and all smallend and bigend housings are checked for overheating.
Cam Shafts
Re-profiled or new with all new hydraulic cam followers.
Oil Pump
New and checked for capacity and volume.
Gaskets
All new gaskets and new oil seals of the highest quality are used throughout the engine.
As the full re-conditioning process as listed above, but also includes the following:-
Cylinder Head
Cylinder head is fully gas flowed to the highest quality and checked for flow.
Cylinder Block
Cylinder block is re-bored and machined as necessary. Each bore is cross hatch honed to exact size of each individual piston, is fully balanced by dividing the mass weight.
Oil Pump
New, and again of the highest quality.
Crank Shaft
Linished or re-ground to bottom limits with matched lead copper main bearings and bigend bearings.
Conrods
Crack tested and checked for alignment, checked for ovality and overheating in housings and fully balanced and lightened.
Cam Shafts
New, all profiles are checked for matched quality in both lift and duration as in blue printed.
As Stage 1 but including the following :-
Cylinder Head
Fully gas flowed as Stage 1, but also includes fast road cams and heavy duty valve springs.
Crank Shaft
Fully balanced with flywheel and clutch (if purchased with the engine).
Conrods
Fully balanced and lightened and pistons fully balanced.
As full Stage 2 specification, but including decked pistons and cylinder block, and also including vernier pulleys for optimum cam timing.
Additional Parts for Extra Power and / or Strength
Our modified engines are built for normal Fast Road use, with the emphasis on retaining or increasing torque, but with an increase in BHP, smoothness and gains in petrol consumption, relative to the extra power given.
Bearing in mind that any good camshaft increases BHP but invariably means a loss of torque - the general yardstick is ‘the higher the lift’ the lower the torque. As all of these camshafts do give extra performance, but invariably you will need to re-calibrate the ECU or change to Carbs or Throttle Bodies etc.
Power band is 1500 - 6200. Power increase approximately 12 BHP. Duration 264 degrees. Valve lift is .340"/ 8.64mm. Timing figures 22-62 / 66-22. Full lift 110 degrees. Valve clearance hydraulic.
Power band is 1500 - 6200. Power increase approximately 18 BHP. Duration 264 degrees / 260 degrees. Valve lift is .395" / 10.03mm / .367" / 9.32mm. Timing figures 22-62 / 60-22. Full lift 110 degrees. Valve clearance hydraulic.
Not suitable for standard injection. Power band is 2000 - 6800. Power increase approximately 22 BHP. Duration 270 degrees / 268 degrees. Valve lift is .438" / 11.13mm / .368" / 9.35mm. Timing figures 27-63 / 64-24. Full lift 110 degrees. Valve clearance hydraulic.
Not suitable for standard injection. Power band is 3000 - 7600. Duration 310 degrees / 302 degrees. Valve lift is .420" / 10.67mm / .396" / 10/06mm. Timing figures 49-81 / 79-43. Full lift 108 degrees. Valve clearance .008"/ .20mm .010" / .25mm.
Not suitable for standard injection. Power band is 4000 - 8500+. Duration 320 degrees / 312 degrees. Valve lift is .450"/ 11.43mm / .420"/ 10.67mm. Timing figures 58-82 / 80.52. Full lift 104 degrees. Valve clearance .008"/ .20mm .010"/ .25mm.
We use only top quality genuine Ford cam followers in all our engines.
Hydraulic cam followers are genuine Ford that are used in all our engines.
Mechanical cam followers, these are manually adjusted as a solid lifter and used only with the Rally and Race cams.
To ensure optimum valve timing used for getting the optimum performance from your modified cam shafts.
Made from steel and sold as a pair.
Made from alloy and sold as a pair and a lighter design.
Which includes supplying both verniers and new timing belt.
Only the highest quality used.
Belt Price
19 We do a performance cam belt to fit the 1.6 / 1.8 / 2.0 engines.
Which also includes inspection of water pump and tensioners.
All valve springs are new.
Heavy duty single springs are used for all Fast Road and Road Rally cams. These can also be supplied for the standard engines aswell.
Heavy duty double valve springs are used only with the Rally and Race cams.
Used only with Rally and Race cams as they only fit the double valve springs.
Used on all Fast Road cams and Road Rally cams and can also be used on standard cams.
This process involves machining the rough cast from each of the inlet and exhaust ports, also the combustion chambers to achieve better flow to each cylinder. Increases power between 10 and 15 BHP. It ensures a smoother ‘tickover’. And is more economical.
Cylinder Head is fully gas flowed to the highest quality and checked for flow.
Fully gas flowed as Stage 1, but also includes Fast Road cams and heavy duty single valve springs.
Fully gas flowed as Stage 1 and also includes Fast Road cams and heavy duty single valve springs as Stage 2. Also includes Vernier Pulleys.
This ensures a smoother engine, lowers the tickover speed and allows it to rev freely to its optimum. Engines have a half balance (pistons and cons rods) included in the price. Bottom end balance (crankshaft assembly, refaced flywheel) is included in the price of Stages 2 and 3. It is advisable if you are having a new clutch fitted to have this balanced with the crankshaft assembly.
Which is pistons and conrods.
Which is crankshaft assembly and refaced flywheel.
All our clutches are of the highest quality.
Because of the high quality of our clutches these can certainly be used on standard Stage 1 and Stage 2 for normal fast road use.
There is a choice of two or three different heavy duty clutches, depending on the application and the use of the engine.
Ideal for the increased air flow required on performance engines.
There are numerous air filters depending on the application required from the replacement panel filter to the 57 I Kits, which seem to be more popular.
We set our fitting charges at a very reasonable rate, this is to encourage our customers to take advantage of this very important service. We have very few problems with our engines except when they are fitted, or set up, incorrectly by D.I.Y. or outside agencies, which can mean more expense and inconvenience for you as the fitting is not covered by our guarantee.
Whereas if we fit the engine, the fitting and all the parts supplied are covered by our guarantee.
It is sometimes possible to fit these in one day (old engine removal permitting).
40 Mondeos / Morgans and Kit Cars
These normally take two days.
It is common knowledge that the Zeta engine is greatly restricted on the inlet side of the engine (i.e.: the inlet manifold, throttle body and settings).
42 Weber Alpha System with Throttle Bodies
This includes 2 x Alpha throttle bodies. JR air filters. Throttle linkage system. Inlet manifold and fitting kit. Alpha engine management system. Fitting instructions and setting procedure. With the 1.8 version it is known to boost the power to 155 BHP on the 130 BHP version, it also boosts the 2.0 version from 128 BHP to 165 BHP. These kits release the performance potential of the production Zetec engine. A complete kit that covers both the fuel injection and distributorless ignition requirements, in a fully integrated package. The kits are supplied with a lambda sensor and can operate with exhaust catalytic convertors. The kits are fully calibrated for a standard specification engine. For other states of tune please contact us.
43 Weber Alpha System with D.C.O.E.’s
This kit consists of 2 x 45 Weber DCOE sidedraught carburettors. Throttle linkage system.
Inlet manifold and fitting kit. Air Filters. Alpha Distributorless 3D ignition system.
Throttle position sensor kit and fitting instructions. With the 1.8 version it will produce 155 BHP with 130 spec cams and on the 2.0 version 128 BHP is known to be boosted to 165 BHP. WEBCON have combined the legendary WEBER DCOE carburettor and the hi-tech ALPHA system. This proven combination releases the performance potential of the production Zetec. A complete kit that covers both the fuelling and ignition requirements, in a fully integrated package. The kits are fully calibrated for a standard specification engine. For other states of tune please contact us.
44 Performance Exhaust Systems
Performance exhaust systems can greatly enhance the breathing of the engine getting the exhaust gasses out much more efficiently.
There are many to choose from most of which we do supply and fit, hence P.O.A.
As above but not as widely available as the systems due to the different applications and more often than not the intrusion of the catalytic convertor.
47 Performance Braking Systems
A must if you are thinking of tuning your Zetec.
48 Performance Braking System Kit
The kits are varied depending on the application, from the basic kit which includes different brake pad material, different brake hoses (braided steel) and racing brake fluid to the full kit which can include all the above mentioned plus different brake discs, different callipers etc.
49 Performance Braking System Fitting
This is very important that it is fitted correctly. We would certainly advise that a performance braking system is fitted by ourselves or a reputable firm that specialises in this type of work.
50 Advice on Braking and Suspension
Very important in the way the car performs. If the braking and suspension system have not been maintained to a high level, we often find that when fitting a performance engine or performance parts to your own engine, it tends to show both for what they really are. So be warned.
A must for those who wish to improve the handling and ride.
As with the braking system, there are many to choose from and it really is a case of "How far do you want to go" !. They can all make the car handling better, but can make the car have a much harder ride, depending on how far you go.
As with the brakes, we would advise the same with the fitting of the suspension kit. We can either fit the system ourselves or again we would advise having it fitted by a reputable firm that specialises in this type of work.
The radiator is sent away (unless new) and is tested under pressure to clear sediment, check rate of flow, repair minor leaks and finally resprayed.
At cost price. With your vehicle’s registration number - then underneath the number, Specialised Engines Stage 1, 2 or 3 as applicable. Price per pair.
These are new genuine Ford short blocks.
The block assembly consists of the cylinder block, the crankshaft, the pistons and the conrods which come fully balanced. All parts used are new.
New genuine Ford units complete with valves.
59 1.6 / 1.8 / 2.0 Zetec Stage 1
Stage 1 as reference 27 but all the work is done on a new cylinder head.
60 1.6 / 1.8 / 2.0 Zetec Stage 2
Stage 2 as reference 28 but all the work is done on a new cylinder head.
61 1.6 / 1.8 / 2.0 Zetec Stage 3
Stage 3 as reference 29 but all the work is done on a new cylinder head.
Brand new genuine Ford.
We take a brand new genuine Ford oil pump, strip it, check it and Blue Print it.
Brand new genuine Ford. We can supply both front wheel drive and rear wheel drive depending on your application.
65 1.6 / 1.8 / 2.0 Zetec New Flywheels Lightened
We can lighten the flywheel on all Zetec engines which can help the engine rev more freely, again depending on application.
Brand new genuine Ford Turnkey units.
67 1.6 / 1.8 / 2.0 Zetec (Full Engines) Turnkey
We offer a full range of these engines from 1.6 through to 2.0 in turnkey form, which means they come complete with gearbox and all ancillary equipment and are ready to fit. These are ideal for kit cars.
Every engine is completely hand built and is the sole responsibility of one engine builder. We much prefer you to inspect your engine before full assembly i.e.: before sump and cylinder head are fitted. This way you can see all the work that has been done and also all the new parts that have been used, including seeing all the modifications that have been done. We also much prefer for you to see the engine removed if you are having the engine fitted, this is so that you can see the condition of the ancillary components. If you are unsure we can at all times advise you.
As with all our conversions please ensure braking and suspension are modified to suit extra power. WARNING - Do not expect any new engine to perform to it’s best until it has done at least 4,000 miles, also oil and petrol consumption can be greater until the engine has loosened up. D.I.Y. Fitting - Do not bite off more than you can chew as the bishop said to the actress. Please read fitting advice on the invoice.
‘SPECIALISED ENGINES’
‘MONDEO’ DEMO
NSTRATORTHE STORY SO FAR
Our ‘Mondeo’ was originally a standard 1800 Zetec fleet car owned by ‘Performance Ford Magazine’ until one fateful day when the piston and con rod decided to leave the sump and travel in the opposite direction down the A2 - Never to be seen again !! They delivered the car to us for assesment, and then decided it was an uneconomical to repair. We brought it from them, took out the 1800 Zetec engine and replaced it with a modified 2.0 Zetec engine, so this is where our story begins.
Our 2.0 engine had a full engine balance. We linished the crank and retained standard size for strength. We fitted heavy duty mains and big-end bearings, new oil pump, overbored the block to .5mm, with Hepolite pistons, the Pistons and Conrods were balanced, we gasflowed the cylinder head, new bronze liner valve guides, standard size valves, three way valve seat cutting and fitted a pair of 270 Piper Cams which were cut from blanks.
16 new hydraulic lifters were fitted, Vernier Pulleys for optimum timing, 2.0 Zetec Flywheel and Clutch, the 130bhp throttle body, specially fabricated four branch exhaust manifold and a special catalytic converter for extra power.
‘Ahmed Bajou’ the Ford electronics wizard has run a series of tests and set up the electronic control unit (E.C.U), Next came the power run tests on John Mowatt's Rolling Road, Pound Lane, North Benfleet, Essex, (01268 728227).
Result : 118BHP @ 6,000 RPM @ The Wheels
This equates to between a minimum of 146.32 at the Flywheel (24%) to 148.68 BHP 26%
We believe the true figure is between 153-155 BHP as we have 'lost' around 7 to 9 BHP thro' the tight new engine (2,600 miles) and the original worn suspension and transmission (97,00 miles!).
The major bonus is the driveability i.e. gains in torque allowing it to pull away in second gear and change directly into fifth and still pull smoothly.
In future we will be fitting the Weber throttle body and ignition system which will also be tested to see what further gains it gives.
We will be updating this on our website as it happens.