2.0 Zetec into 1.6 Si - full conversion guide.

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Postby Thumbs on Mon Jan 02, 2006 5:50 pm

1) If i use the 1.6 Flywheel, do i have to use a 1.6 clutch or a 1.8 clutch as i plan to fit a MK6 Escort Si 1800 Gearbox if the starter is on the front?
A: Don't think this gearbox is a straight fit (dont quote me tho) 1.6 and 1.8 fiesta clutches are the same

2) I know i need to change the Inlet manifold because the 1.6 is restricive, is this the same case for the ehaust manifold? Or can i use the 1.6ehaust manifold?
A: You can use the 1.6 exhaust manifold (it is believed to be the same as the RS1800 one)

3) What code do i need for my ECU, i think it was DEEP, DESK or DEWY? Correct?
A: CORRECT
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Postby G6Griff on Tue Feb 07, 2006 9:36 pm

Do you use the same injectors from the 1.6 or from the 2.0? are these the same??

is it worth the effort of getting a 1.8 manifold or is it nominal?
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Postby Dazza on Wed Feb 08, 2006 2:36 am

the_hammerite_avenger wrote:Are you suppose to use the 2.0 crank position sensor or the 1.6 one? Its on the front of the block, little black plug just below the exhaust manifold on the gearbox side?


The sensors are both the same so use which ever looks the better.

G6Griff wrote:Do you use the same injectors from the 1.6 or from the 2.0? are these the same??

is it worth the effort of getting a 1.8 manifold or is it nominal?


Use the 2.0 injectors aslong as you have 2.0 managment such as ECU and MAF.
As for the Inlets I dont know, Iv wrote a guide on how to fit the 2.0 Focus one - That'll be the best or if not the RS1800 one as the ports are bigger than the 1.6
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Postby adz on Wed Feb 08, 2006 2:38 am

wicked, this should come in useful soon. Hav a 1.6si as a donor car, and my 1.1 hcs to put it into...
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Postby corley on Wed Mar 08, 2006 7:40 am

Hello, Im fairly keen on performing the 1.6si – 2ltr conversion, I was just wondering if anyone could help me out with some very basic questions.

Where would you normally go to hire an engine hoist? Phone up a garage?

Where would you normally get a 2ltr engine from, could I just buy a used mondeo car off of auto trader and use its engine, this way I know it works to, and when I look out for a engine, do I look specially for 2ltr mondeo zetec, or are all 2ltr engines zetecs/compataible.

Thanks for any answers!!
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Postby Dazza on Wed Mar 08, 2006 12:27 pm

Welcome Corley!

Tool hire companys will be able to loan you an engine hoist (Such as HSS) and for the engine, unless you can get a mondeo for around £150 give or take I wouldnt bother - Your after a 2.0 zetec engine from a mondeo 93 - 96ish and when you look at the camcover it should be silver and NOT black

You can fit the black top (camcover) engine but it is more work i.e different engine mounts etc
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Postby corley on Wed Mar 08, 2006 12:40 pm

hmmm, only place i can rly think of is auto trader to get a real cheap mondeo, but there like 350-400+ :(( damn, and silver camcover aswell, any other things to look for that show an engines a zetec? cheers
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Postby Dazza on Wed Mar 08, 2006 12:43 pm

http://www.find-a-part.co.uk (or maybe .com :-? )

Your just after a silvertop 2.0 zetec engine from an early mondeo. If you use that link above you'll get one easily enough - No point buying the whole car
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Postby corley on Wed Mar 08, 2006 1:03 pm

but if i buy the whole car i have all the extra bits n bobs i need like the ecu and other stuff right? + then i know the engine works aswell - well hopefully lol, or am i being a bit silly opting for the lot
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Postby Dazza on Wed Mar 08, 2006 1:22 pm

That website wont give you a fooked engine. All you need is the engine and ECU (Certain ECUs only, best to try eBay)
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Postby corley on Wed Mar 08, 2006 2:07 pm

i jsut need the 2ltr zetec ecu tho, i could get one from the scrap yard coudnt i?, tbh im not 100% sure what they llok like altho my mate does, are they hard to take off an old mondeo at a scrappy?
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Postby lucasdemoley on Wed Mar 08, 2006 6:47 pm

Dazza_CW wrote:Welcome Corley!

Tool hire companys will be able to loan you an engine hoist (Such as HSS) and for the engine, unless you can get a mondeo for around £150 give or take I wouldnt bother - Your after a 2.0 zetec engine from a mondeo 93 - 96ish and when you look at the camcover it should be silver and NOT black

You can fit the black top (camcover) engine but it is more work i.e different engine mounts etc


How do you tell the difference between a series 1 and series 2? The 2nd one would be the one to look to get really isnt it?
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Postby Luke_Si on Sun Mar 19, 2006 12:58 pm

Hi M8,
You can tell the deffence on the rocker cover the series one's have DOHC 16V on them the series two have 16V Zetec on them.

I have had 2 series one's and they both been fine. One died because I had a oil leak and could not be assed to pull over and call the AA so I blow it up. LOL

There cheap as chips £100 jobs a gooden but I do know the owner of the scrapy.

Tips

What ever one you get it would have been standing for a while so once its in the car, remove the rocker cover and pure oil over all the cam followers and let it soak though and repeat a few times or else you get a bad tapping sound, found this out the hard way on the first engine.

Also if you use the series one engine use 5/30w Oil and 10/40w for the series two engine.

Its because the series one has a problem with sticky vavles.

Also you dont need to change the oil pump just use 1.6cvh oil filter works a treat.

Also while the engine is out buy your self a cam belt kit and a new water pump as saves you doing these things while they are in the car trust me its not fun. And for the cost its worth doing.

If you need any more tips or advice msn me or pm me msn name is LukeC64@hotmail.com.

Luke
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Postby Philly on Thu Mar 23, 2006 2:07 am

hiya guys am new to the site and have read through the post twice now.

have managed to get a 2 litre zetec, gonna get inmy fez.

the fez is a 1.4 cvh though, is it worth fookin it off for a si or is it still poss, if so any help and tips would be so much appreciated, if any one could message me or email me it would be easier as i dont get to use a computer much but i will still keep checking. many thanks guys :D :D :D
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Postby Luke_Si on Sun Mar 26, 2006 11:33 am

There is a guide on here on how to do this but it involes more work as u got to get the si engine wiring loom and so on.
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Postby lucasdemoley on Sun Mar 26, 2006 10:04 pm

Cheers for help luke_si.

Found this gasket set on ebay, is this right for all the bits at the top of the engine? Im assuming i'd just need the gasket for the sum then or am I forgetuing abit(and is this a good price)? With the water pump, can i just use my original one, or is it really sensible to change itfor a new one (says in the guid just to use si one). Also, with the cam belt kit, can i happily do this myself, or is it difficult to do due to one cam maybe moving and being in the wrong place compared to the other one?

Heres the link so if it is right, other peeps can use the link to buy the bits needed as he sells them all the time,

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=4623374520&ssPageName=MERCOSI_VI_ROSI_PR4_PCN_BIX_Stores

cheers for help
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Postby Luke_Si on Tue Mar 28, 2006 8:19 pm

Not a problem with the help man.

Its wise to get ur self a new water pump I got mine non new ford part for 25 pound which is good. Mine went and a mate who done a mi16 in his 205 said change the water pump while its out and I was like yeah ok what ever then I payed the price so for the extra money worth doing.

To do the cam belt set the engine is TDC which stands of TOP Dead Centre.
You do this by some one turning the crack clock wise and with the spark plug out of pistion one which is the close to the crank side u wait intil it blows air out the hole then its stops and then its there check with long screw driver and then mark on crank so u can line back up.
To lock the cams you need a pice of steel 5mm thick and about 200mm long at a guess for lenth to put on the slights of the cams u cant miss them and they only go in one way so if the metal dont fit then u know ur not there then u can losed the tensor and remove belt and plastic pulls to fit new ones.

To refit the belt do the cams first as they dont move then work down to the crank and if you need to move one cam slightly then move it back to tighten again and lock them again fit tensioner and done. Turn engine 10 times to make sure nothings jams if it does then ur not going to cause damage check and done.

I would recommand a hyanes manual this is all in there with pics but if you need any help pm me and i will send you my email address boss I am always online LOL.

P.S that kit is perfect for what u need mate :)

Luke.
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Postby p.whitelock on Thu Apr 27, 2006 6:51 pm

Thumbs wrote:engine is in totally standard. Read the guide very carefully, pay attention to the parts you NEED to use from the 1.6 engine ie. water pump (2 litre pump runs wrong way), oil pump (2 ltr pump causes filter to hit fezzy bulkhead).

It's quite easy really, it only took me so long cos I stripped, cleaned and painted every single part I could. Otherwise I recon a weeks work solid would be plenty of time.

You do really need a RS1800 inlet manifold and the 2 litre ecu but it will run with 1.6 stuff (as mine is temporarilly) just will be down on power a bit and under fuel at high end revs, not good long term. I plan to run a Trust inlet manifold to improve breathing and increase space in the bay (£150), and the 2 ltr ecu is a must (£25 from scrappy).

PM me if you need any more pointers, as it's fresh in my mind :)


Hi, i have recently bought a trust electrical inlet manifold from ebay for my cougar. its the 2.0 zetec engine same as yours. is it as good as iv been told? im hoping to get it fitted in next few weeks. Also how easy a job is it? Thanks.
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Postby p.whitelock on Fri Apr 28, 2006 7:17 pm

Guessing no one knows or can be bothered replying then :(
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Postby Thumbs on Wed May 10, 2006 7:32 pm

I don't get online very often and I not many people on hear have a trust manifold.

I have replied to your PM but didn't notice you are fitting it to a cougar.

The manifold to throttle body pipe should fit your cougar OK.

The ICV you have on the cougar should be same design as the mondeo so you'll be able to use this is you folow my brief instruction.

e-mail me if you need some more info.

Craig
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Postby paradox on Wed May 10, 2006 8:10 pm

p.whitelock wrote:
Thumbs wrote:engine is in totally standard. Read the guide very carefully, pay attention to the parts you NEED to use from the 1.6 engine ie. water pump (2 litre pump runs wrong way), oil pump (2 ltr pump causes filter to hit fezzy bulkhead).

It's quite easy really, it only took me so long cos I stripped, cleaned and painted every single part I could. Otherwise I recon a weeks work solid would be plenty of time.

You do really need a RS1800 inlet manifold and the 2 litre ecu but it will run with 1.6 stuff (as mine is temporarilly) just will be down on power a bit and under fuel at high end revs, not good long term. I plan to run a Trust inlet manifold to improve breathing and increase space in the bay (£150), and the 2 ltr ecu is a must (£25 from scrappy).

PM me if you need any more pointers, as it's fresh in my mind :)


Hi, i have recently bought a trust electrical inlet manifold from ebay for my cougar. its the 2.0 zetec engine same as yours. is it as good as iv been told? im hoping to get it fitted in next few weeks. Also how easy a job is it? Thanks.



ahhh your the bloke who bought that.
It went for a little too much money for my liking oh well you win some you lose some.
Good luck with fitting it and i hope it serves you well.
if it doesent fit or you decide to sell it further on in time may i please have first refusal on it.
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Postby lucasdemoley on Wed Jun 14, 2006 1:17 am

If someone is doing this convo in the next few weeks, can they post some pics up of the process, just for numpteys like me, lol! I'm planing to do mine now (engine all sorted etc) in the next few weeks so will take pics and post them up if no-one else does.

BTW, can I use any paint on the engine, or does it have to be break caliper heat stuff, and will one pack do or will I need a few? Also, can the exhaust manifold be painted in any way? cheers.
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Postby Cage on Wed Jul 05, 2006 2:02 pm

yeah you can fit an oil filter from a cvh engine to give you the clearance you need.
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Postby VUK on Thu Jul 06, 2006 5:30 pm

done this conversion in 12h :)

2 days max.... if you know what you are doing
1995 Fiesta SI 3 door, green something, 2L + diesel gearbox in(130mph @ 5,000rpm :o), focus inlet in, + k&n, passed mot without a cat :D < FIESTA FOR SALE! GOT A BMW 528I SE MANUAL NOW :)
http://www.finalgear.com
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Postby deepspace on Tue Jul 11, 2006 3:19 pm

Does any of the parts of the 1.4Si engine comply with the 2.0 Ztec engine change?
:D Eye for the Art...

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Postby lucasdemoley on Tue Jul 11, 2006 3:31 pm

I'm pretty sure the 1.4si is alot different, and that its probibly similar conversion to the 1.1-2.0. At best, i the loom might still be able to be used, but i doubt it. This is just going from memory of what others have said about the 1.4si, but could be worng *awaits to be corrected :lol: *
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Postby VUK on Mon Jul 17, 2006 7:21 pm

Can I just add that the 2.0L weights just about exaclty the same as 1.6/1.8
1995 Fiesta SI 3 door, green something, 2L + diesel gearbox in(130mph @ 5,000rpm :o), focus inlet in, + k&n, passed mot without a cat :D < FIESTA FOR SALE! GOT A BMW 528I SE MANUAL NOW :)
http://www.finalgear.com
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Postby hasheyb on Wed Oct 11, 2006 3:25 am

I have never noticed a weight differance, just alot of torque steer at times but i think thats partly because i have 16"s and lowered 60mm.
Tis alot of fun though! :lol: :lol: :lol: :lol: :lol: :lol:
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Postby Jonezy on Wed Oct 11, 2006 10:00 am

adz wrote:one problem, insuring it :bonkers: lol, im only 17 so im not going to be doing anything like this for a good few years. how old are you and who are you insured with if u dont mind me asking?

ive always been interested in doing something like this since renton (redline) put a cosworth engine in his bmw (see sig)

also my mate put an r5gt turbo engine in his clio (see video)
http://www.1an.co.uk/adey/100_0532.mov

cheers
adz :D


id like one in ma 1.3 too, what insurance cost can i expect as a named driver, as a stab i the dark. as the focus 2ltr is only grp 8/9 insurance it shouldnt be much more as ma 1.3 is grp 7/8.

and what companies should i use for insurance ive heard hyperformance are good for this typa thing.
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Postby lucasdemoley on Wed Oct 11, 2006 10:58 am

IM with redline insurance. Still costs £1000 at 21. DOnt do this at 17 cos youll end up in a hedge! Also, insurance companies wont be blind to the fact that youll be driving the car. I cant put my 19 yr old gf on my insurance, they wont let me, which i think is a good thing!
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Postby onslack on Mon Oct 16, 2006 7:16 pm

excellent guide :Q , used it for my conversion and followed it to the letter
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Postby mikeysabes on Thu Nov 30, 2006 1:44 pm

what clutch do i use ?

a fiesta one or mondeo ?


as i need to get a new clutch for the conversion
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Postby Smo on Thu Nov 30, 2006 1:48 pm

Fiesta one, as you'll be using the Fiesta flywheel :)
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Postby mikeysabes on Thu Nov 30, 2006 3:11 pm

Sweet,

now i just need the RST gearbox and decent`ish clutch
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Postby Smo on Thu Nov 30, 2006 3:32 pm

If you're going for an RST gearbox, get an Escort one as the LSD will make a big difference :)
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