Zetec engine build

Last Updated on December 31 2015

February 2008

This is the project to build a new Series II/Zetec E engine, on a shoestring. The engine will feature raised compression ratio, steel rods, forged pistons, a CNC head, Race cams with hydraulic lifters, and a predicted power output of around 220BHP.

The engine should also feature an electric water pump, and maybe a dry sump system, depending on how far the budget stretches.

So far, I've sourced a 2.0 Series II Zetec-E from ebay for £225.00. The engine has 71,000 miles on the clock.
I've also ordered a set of Series III Focus Eagle rods, and JE 10.5:1 pistons from the USA, cost £450.00.

Zetec engine Zetec engine Zetec engine Zetec engine Zetec engine

March 2008

Here is the spec of the rods and pistons I've bought from the States in March 08.

Ford Focus Zetec - Eagle "ESP" 3-D H Beam Connecting Rods - 5.483"
Eagle "ESP" H Beam Connecting Rods Feature:

    * 2-Piece forging for increased strength
    * Silicon bronze bushings for floating pistons
    * Multi-stage heat treated
    * Packaged in weight matched sets
    * Certified 4340 steel, vacuum degassed to remove impurities
    * Each forgins is x-rayed, sonic tested, and magnafluxed to insure quality
    * All surfaces are 100% machined
    * Shot peened to stress relieve the metal

JE 10.5:1 Pistons with JE Pro Seal Rings, Ford Zetec 2.0L DOHC ZX3 00-01 (85.00mm bore)
Ford - Zetec 2.0L DHOC ZX3 00-01

JE Pistons Feature CNC machined side reliefs, diamond turned skirts and contact reduction groves as standard, these pistons are the ultimate answere to the special demands made by today's monster sport compact engines. Designed to handle high Nitrous and turbo applications. Dome/Dish requires no deburring or preparation, Dome and dishes feature smooth flowing radii for excellent flame travel .2618 T6 high tensile forged aluminum JE designs are specifically engineered for extreme applications up to, and including, professional competition. In this environment, the higher compression ratios, highest boost or heavy nitrous usage necessitate the higher tensile strength 2618 aluminum alloy 1.0 x 1.2 x 2.8mm ring widths. .787 x 2.250 straight wall carbon steel wrist pin provided.

Skirt style: Full Round Skirt
Piston Set Includes:
# Wrist Pins
# Wire Locks/Spiro Locks
# Piston Rings, Pin fitting and wire locks

The link to the Eagle rods is here: http://www.eaglerod.com/products/Ford/4cyl/4cyl%20rods.html
The link to the JE Pistons is here: http://www.jepistons.com/cat/je/sport/ford/zx3.shtml

June 2008

This month will feature the strip down of the engine, the machining to accomodate the 85.00mm pistons, the build up of the engine, and further decisions surrounding dry sumping the engine.

This table shows the dimensions of the standard Zetec-E engines.

So the JE Pistons I bought are 3.346" or 85.0mm bore, which will mean a rebore of 0.2mm is required. The bore area therefore will be 8.5cm x 8.5cm x 3.14159 / 4 = 56.74 square cm.

Volume of 1 cylinder is bore area times stroke = 56.74 x 8.8cm = 499.35cc

As there are 4 cylinders in the engine the total engine volume is 499.35 x 4 = 1997 cc

I've also weighed the block, crank and cylinder head to establish some base weights.
Block : 35KGs
Crank : 15KGs
Head : 18KGs (without cams fitted)

Monday 23rd June 2008
I've taken various bits over to Chesman Motorsport in Coventry to get the block bored, acid dipped, and the crank lapped. The price of the rebore is around £100 for the four cylinders.

August 2008

I sold the engine, rods, pistons and all the other bits from the 2.0 Zetec. This project page is now closed.