Update Ten
Get yourself a coffee as this update is a big one!
In the quest for more power i considered a few more options, if money was no object then a turbo/supercharger or even independant throttle bodies and this will get my 1.8 to 170bhp N/A and beyond with Turbo/Supercharging.
However i came to the conclusion that i should start with a BIGGER base.
Enter the 2.0
Silertop Zetec from the MK 1 and Early MK 2 Mondeo's (Up to 1997)
I bought a 1.8 gas flowed head
The head came bare, so i had to build it up.
It took me a few days (bit by bit) to lap in the valves, fit new
stem seals, valve springs and the collets.
The valve springs and collets were the worst as i didn;t have a
vavle spring compressor... Tis amazing what a pair of pliers and
a g-clamp can do!
Right, the problem with the Mondeo Engine is that it only fits in a Mondeo.
It needs to be
stripped to a Bare Block and Head, then fitted with escort
ancileries.
Because of this, a great deal of prep is needed before swapping
engines, below is a list of parts that need swapping for ESCORT
bits.
Sump,
Oil Pump
Oil Pickup Pipe
Dipstick
Water Pump
Flywheel
Before anything
else... the bloke that delivered my engine cracked the sump.
Spilt oil in my porch.
Scrap yard replaced the sump free of charge with that of an
escort, and pickup pipe to match...
So apart from a gallon of oil on my floor, they did me a favour,
lol.
The 2.0 engine was stripped of the useless mondeo ancileries,
pulleys... sump/oil pickup pipe ready for the escort items.
Cam belt covers
removed
Cam belt off
Oil Pump and water pump removed
Block and sump cleaned and painted and first signs of removing
the 2.0 head.
Head Removed
The 2.0 block
The old HG on
the 2.0 block.
2.0 Oil pump and Flywheel
Differences between the escort and mondeo oil pumps.
Mondeo and escort Flywheel's
1.8 oil pump and new 1.8 water pump fitted.
2.0 Flywheel Removed
1.8 Escort flywhel Fitted.
(pic taken the day before the swap, swap was done at my parents
house 5 miles away)
Make shift Garrage at my parents. The bank holiday weekend
promissed rain.. and it pissed down on the sunday.
Nearly everything refitted...
Lil vid made by
my bro... First time we fired it over...
http://s63.photobucket.com/albums/h146/hardhouseheaven_uk/?action=view¤t=100D3864.flv
2.0 ECU - DEWY
£30 on ebay!
Following aguide for swapping the 9 wires in the ECU connector, i
swapped the 1.8 ecu for the 2.0 one.
(When i have time, i shall post some guides on the site)
I now have a 2.0
zetec with a Gas flowed 1.8 head. The valves are the same size
but being a 1.8 head its raised the compression ratio from 10:1
to about 11:1, maybe a little higher as the head was skimmed as
well.
Couple this with the Ashley 4-2-1 Manifold, Decat and Magnex
exhaust and of course the good ol k&n pannel Filter and it
should be at the 150bhp and 140lbs.ft mark (RS2000 Power)
The 2.0 zetec in standard form is 134bhp and 133lbs.ft,
My hope is the freeer flowing head, filter, manifold and exhaust
has helped up bhp output while the increased compression adding
valuble torque.
What it cost me...
2.0 Silvertop Zetec
(From Car Breakers)
£100 delivered
Stage 2 Gas Flowed Head
£150
Head Gasket set
Motormainia (With blagged discount
£48.99
Stretch bolts
Motor-world
£8.99
New Genuine Ford Cambelt Kit + Tensioner
Free!!!
(Given for free by a mate)
1.8 Water Pump + Gasket
Motor-world
£29.99
1.8 Oil Pump Gasket
Furrows - Ford
£2.04
1.8 Sump Gasket
Motor-world
£8.99
1.8 Zetec Oil Filter
Motor-world
Leaving present...
1.8 Oil Pickup Pipe Gasket
Furrows Ford
£0.82
1.8 Oil Pickup Pipe
(From scrap yard)
FREE!!!
1.8 Oil Pump
(From scrap yard)
£5
1.8 Flywheel
(From scrap yard)
£5
1.8 Sump
(From Scrap Yard)
Free
1.8 Alternator
Taken from Original Engine
1.8 Starter Motor
Taken from Original Engine
1.8 Clutch
Taken from Original Engine
2.0 ECU (Code: 93BB12A650EE - DEWY)
Ebay
£35 Posted
1.8 Oil Dipstick + Pipe.
Taken from Original Engine
Spark Plugs + Leads
Taken from Original Engine
Coil Pack
Taken from Original Engine
Thermostat Housing
Taken from Original Engine
1.8 Inlet Manifold + Thottle Body
Taken from Original Engine
4-2-1 Exhaust Manifold
Taken from Original Engine
Engine oil - 10w40 (just for a few weeks then good quality 5w30)
(Screwfix - with discount)
£8.79
Temp Gauge sender
Motor-world
£8.99
2.0 ECU
£30 Ebay.
Total Cost about £440ish i think.