Step by step Zetec installation - Page 4

Last Updated on December 31 2015

8. Create a new engine mount

Front engine mounting fitted New engine mounting
Normally, the front of the X-Flow 1.6 or 1.3 engine is connected to the chassis rail at the end of the block. Because the chassis rail needs modifying to clear the cam belt pulleys, the original mounting point has to be removed when the chassis is modified. Also, theres no place for an engine mount at the end of the Zetec block anyway, so I had to make my own additional mounting point. I looked around at Mk3 Fiestas 1600 Zetecs to see how they mounted the engine, and after some thought, decided to use the Fiesta Mk3 RS1800 Alternator mounting bracket (cast iron which bolts to the front of the Zetec engine) and a Fiesta Mk3 Gearbox mounting rubber mounted to the chassis, as shown in the pictures.

Prototype and final mounting brackets
I welded a 5mm steel plate at a 45° (approx) angle to the chassis rail, and then using cardboard as a template material, made a bracket to support the engine on the mounting rubber. Once I was happy with the template, I used 1.5mm steel to make a test bracket (the silver one in the picture), and once that was proven to work, I made another bracket, this time from 5mm steel.

9. Create an engine steady bar / tie bar

Engine stabiliser
The engine is probably going to want to leap out of the car under extreme driving conditions, so now is a good time to fabricate an engine steady bar. I've welded a mounting bracket to the front bulkhead, and the engine mounting runs from the bulkhead to the side of the engine block.

10. Relocate the brake servo / replace with a Pedal Box

Relocated brake servo brackets
If you decide to retain the braking servo, then you'll certainly have problems with clearance. The ignition coil pack sits on the end of the engine, and the servo gets right in the way. Either relocate the igntion module, or relocate the servo brackets.

Why not fit an Escort Mk2 Pedal box from Rally Design, and save a whole load of weight? I carried out this conversion in 2006, and have been very happy with the results. See the Brakes page for more information. Note that master cylinder reservoirs are not allowed inside the passenger compartment. They present a fire risk, and are strictly outlawed in motorsport in the UK. So reservoirs must be located inside the engine bay.

So thats it then?

Engine running Single piece drive shaft
Well, sort of. The engine will now fit in the engine bay, but theres still more work to do.

On the Mk1 Fiesta theres a two piece drive shaft thats supported by a bearing on the back of the engine. You can't fit the bearing to the same place on the Zetec engine, because theres no place to bolt it to. So my advice is to upgrade now to the Mk2 driveshafts, which are tubular and theoretically stronger anyhow.

Fiesta Centre offside Tie Bar kit
The alternator was a challenge to fit. I bought a Powermaster 'Denso' race alternator. Its probably the smallest alternator you can buy at 93mm, and space is at a premium down the front of the engine. I also had to buy a special mounting bracket from Brise (the suppliers of the alternator) to fit the alternator. Apparently an alternator from a Formula Ford racing car will fit, again using the same mounting bracket that I've used. Maybe its the same as the Denso type I've used.

And then theres a problem with the alternator pulley fouling the TCA Tie Bar. The Fiesta Centre sell a Tie Bar kit which you can use to replace the existing Mk1 tie bar, and it gives you plenty of room where the alternator sits, so it's a worthwhile modification in the circumstances. However, the handling is less than ideal with the kit on the car, as the tie bars are too long and you end up with no caster angle on the front suspension.

4 branch manifold(header)
You'll have to get an exhaust manifold built. I've opted for a 4-2-1 manifold, supplied by Ashley Performance Exhausts. They kept the car for a week to hand fabricate the manifold and system. I told them I wanted as quiet a system as possible, and they obliged by fitting a Golf GTI 16V silencer, and the car now only registers 94db at 4000 rpm, which is very, very quiet. Nice! The pipe diameters are 2.25" for the final system, 1.85" for the two collectors, and 1.5" for each of the four branches on the manifold itself.

Fiesta RS1800 radiator
As far as cooling goes, I've used a Fiesta Mk3 RS1800 radiator, with some custom silicone 45mm -> 32mm x 150mm reduction hoses to connect the engine to the radiator. These hoses aren't off the shelf items, so you'll need to contact to manufacture them. I have heard of the Mk2 Fiesta XR2 radiator being used, though I've not seen how the plumbing is routed.

There's no other traps to fall in to. Its not a job for a weekend by any means. Indeed I started my transplant in 1998, but theres a lot of other jobs I've had to contend with, like fitting bigger wheels, bodykit, roll cage, fuel system, injection system, uprated brakes, new wings and sills, respraying the car, keeping the web site updated etc etc.

And finally, just in case you'd forgotten (I know I had) what it looked like, this is how a standard 1600 Crossflow powered XR2 should look, alongside my 2.0 16V Zetec conversion.

Standard Original XR2 engine My Zetec engine