Established 22 years
Step by step Zetec installation - Page 2Last on March 28 2017
So just what are the 10 steps to installing a Zetec engine?
1. Obtaining & preparing the engine
Once we collected the engine, it had to be stripped of the manifolds (headers), emission control equipment, starter motor, power steering pump, alternator etc, until we were left with a basic engine sitting on its sump. This shot shows my rebuilt engine, after the rocker cover was powder coated, and a few bits had been changed like the sump, oil and water pumps etc. More of that below...
2. Change the sump and oil pickup pipe
3. Change the standard Zetec waterpumpWhy? Well the difference between the 1.8 Escort/Fiesta water pump, and the 1.8/2.0 Mondeo water pumps, is that they spin in opposite directions. You see, on the Mondeo there's a serpentine drive belt driving the water pump and ancillaries. When you use a triangulated drive belt setup, the water pump is driven in the opposite direction to the serpentine belt setup (see diagram).
So if you are not using the serpentine drive belt setup, you must change the 1.8/2.0 Mondeo pump for the Fiesta or Escort Zetec 1.8 water pump.
For the later black top, or series 3 Zetec from the Focus, the solution is a reversed impellor from a place called Quicksilver Race Engines in the States, or an idler pulley made up to run the pulley in the same way as stock.
The two pictures below show the two different arrangements for driving the water pump. The serpentine system, as used on the Mondeo, and the triangulated system, as used on the Fiesta.
Key to pulleys: A = Alternator, W =Water Pump, C = Crankshaft
The Serpentine system (Mondeo)
The Triangulated system (Fiesta)