fiestaturbo.com

[AndysFatRS]

This is my first attempt at doing a guide but as i am currently attempting a very cheap zetec turbo build i thought i may as well try and make a guide

The Base engine is the 2.0 series 2 zetec out of my written off Si, so luckily there i know the engine is good and strong. First job was to strip the engine completely to check parts for wear, may as well now as a turbo will find any weak spots. So all engine mounts removed, alternator, water pump, power steering pump and brackets removed. Cylinder head removed, sump removed, oil pickup, main caps, crankshaft, rods and pistons all removed so i was down to a bare block.
with the block inspected it was found that there was virtually no wear to the bores ( honing marks still clearly visible despite me having done 10,000 miles with that engine and having not known it had been reworked as it came from a scrappy!)
almost all the engine was in brand new condition except every shell, main AND big-end were knackered. made no noise though?

I ordered a de-compression plate from Ferriday Engineering

ordered some shells as well, picking them up tomorrow £55.
had a look at the piston condition, noticed something strange , but good whoever honed it has put some slipper pistons in! as in pistons with a Teflon coating on the skirts to make it Rev-happy!

Picked up some ARP products today from Road&Stage motorsport in Morcambe as i felt these were pretty much a requirement. So i got rod bolts and head bolts

while i am waiting for parts to arrive i cleaned up the Block and painted it in the only colour i though it should be

Block

because i am building on a budget, and because i couldn't afford it, i decided to use the Zetec inlet manifold instead of buying adapter plates. But as i am using the existing RST management i have to fit the Throttle body, fuel rail/injectors, and iscv to the manifold. So using a peice of 5mm (5mm is the perfect thickness to allow the throttle linkage to not catch on the manifold) aluminium an adapter was made up to fit the throttle body to the manifold, using the top-right bolt hole as a common point.

The zetec engine uses side-feed injectors in a sandwich plate and the RST end-feed bosch injectors BUT... if you remove the side feed injectors from the sandwich plate people say the bosch injectors are too small to fit, at this point look at the end of the zetec injectors, 9 times out of 10 stuck on the end of the injectors are some small 'buckets', these are adaptors to seat the injectors. if you remove these from the injectors and fit them back into the plate where they should be you will find your bosch injectors now sit into the manifold. i will describe the mounting of the fuel rail at a later date when i can take some pictures.

As for exhaust i have simply drilled and tapped the zetec head to take the cvh manifold using a manifold gasket from ford as a template

progress updates/pictures coming soon

cheeRS
Andy

[MattPym]

Nice keep it coming!

You mention a fitting 'bucket' on the fuel injectors! Does this mean that the standard Zetec fuel rail can be used with end-fed injectors rather than having to bodge together a fuel rail or use an RST item???


Matt

[AndysFatRS]

no, the rst rail has to be used but the buckets allow the injectors to sit in the sandwich plate

cheeRS
Andy

[MattPym]

Oh right...but this means you can use retain the zetec inlet manifold (or am i completely gone off track)



matt

[AndysFatRS]

no, your right you can retain the zetec manifold

[MattPym]

Nice one...Cool bit of info to find out...Saves me a few quid aswell!


Cheers
Matt

[MattPym]

Also what kind of power are you hoping for/expecting from this build??



Matt

[AndysFatRS]

Today i have rung round a few suppliers and come up with a new genuine ford bottom end gasket-set, triple-layer metal head gasket and the required shells

gasket set

shells

head gasket

in case you are interested the head gasket is actually a bit of a bargain with it being a triple layer metal one as these normally retail for mega money as uprated items, either that or go to Ford and order part No 1071744 -- For £27 inc Vat or £19 at trade
Ford list it as for the Focus ST170 engine but the gasket is indentical, just a lot stronger.

head gasker Finis No

As i haven't got any further today i have taken a few new pictures to show described parts
First picture is of the bore condition BEFORE honing!!!

bores

the next pictures are of a standard zetec piston and the ones from mine. the white patches are reflections.

teflon piston

standard

standard piston

this shows the large injector hole on the zetec sandwich plate

zetec injector fitting

and a quick pic of my goodies!

ARP

Mattpym - Don't know really, im actually only doing the conversion because my cvh has let go dramatically and its cheaper to convert it than to fix it!
i have seen 1.8's with similar specs running 219(ish)BHP so hopefully a little more than that

cheeRS

Andy

[JayC]

good luck mate ill be following this one... what turbo you running?

[Andimav]

Be interested to see it finished..

What colour is the block painted?? Is it any kind of special paint??

[AndysFatRS]

Andimav - the block is just your basic Hammerite Green, i think it looks good though!

JayC - i'll be running the T3 that was on my CVH

right bit of an update, got some work done this saturday. before refitting crank etc.. there was some modifications to be carried out on the block, the breather on the front of the block needs blocking up and a new one being made to the rear of the block

blocked breather

new breather

after fitting the new breather and blocking the old one it was on with the rebuild ( note: the blocked breather plate is secured using the original breather bolts but due to the ERST manifold and T3 the top bolt has to be ground down to allow clearence)

the first job in the rebuild was to 'Hone' the bores using a 'honing' tool and lubricant.

honing

the next job was to re-fit the oil-spray jets and to fit the new main shells, applying oil during the installation

mains

the crank was then refitted, but the crank would not sit correctly, closer inspection showed an installation lug on the centre main bearing, which had to be carefully removed with a small file. the crank was then refitted and sat perfectly and rotated freely.

crank

with the crank in the next job was to re-fit the pistons and rods, these were installed one at a time with the new big end shells and the engine was checked to see it rotated freely after each was installed. the ARP rod bolts were also fitted and torqued up to 27lb/ft three times as per installation instructions using a twelve-sided 3/8 socket

rods/pistons/ARP

the oil pump was re-fitted with the gasket face cleaned from any excess paint

with the main of the engine back together the oil feed and return from the turbo were addressed the oil feed was taken by using an ERST S1 oil feed, this simply installs in the place of the oil pressure switch and the switch then installs in the S1 feed. no drilling no tapping

oil feed

the oil return was a simple fitting threaded into the sump and sealed with loctite

oil return

i then placed the head on and stuck everything together to mock up the engine

zetec turbo

the engine could not be progressed further than this as the cylinder head has been stripped down ready for porting and polishing and the valves to be lapped in.
so as i couldn't be bothered with starting this task i started stripping the car

stripping

cheeRS
Andy

[jimmyesh]

Top work that man!

[disc]

Dude, your camera (phone?) sucks.
This can't be a guide with low quality pics like yours! Try to find better camera.

[HCS PIMP]

nice my si if i keep it will be a nice match similar job

[AndysFatRS]

cheeRS jimmyesh

the progress has been slow of late as i am waiting for parts to arrive ( remote iscv )
but i have lapped all the valves back into the head and have port-matched the head to the ERST manifold to improve gas flow, and hopefully reduce lag.
the exhaust has been heat wrapped and sprayed in VHT black, make it a bit subtler, and hide my poor wrapping skills


lapping the valves


port matched head

i went and picked up a 2.0 sandwich plate today £15 from my local scrappy, picture is next to the 1.6 (top)


more stripping happened with the car and virtually everything came out




battery tray has gone to make room for a GRP A cossie filter



the battery has been connected using a neat little distribution block


and a couple of modifications for some of the extras being sorted while the car is in bits



and the slam panel has been removed because its too much of an arse taking everything out when the rad needs sorting and the new one is about 1/3 the weight!




all of the fabrication work has been carried out by an awsome friend of mine who just seems to be able to do anything his car is on the right and has a nice little engine hiding away

[onslack]

coming along nicely

[AndysFatRS]

got a bit more done this saturday, got up early ( 10.30 !!!! ) and started so stripped the remaining parts from the engine bay, the master cylinder, servo and brake lines. The fuel filter and brackets were also removed and my girlfriend started sanding down the bay while i re-built the head, re-fitting all the valves. Once this was done i joined in sanding the bay and had to stop to go to get some primer, my forward planning is legendary!!
The compressor was fired up and the spray gun dusted off and the bay sprayed in 4 fresh coats of mercury gray, and as i had paint spare i painted the rocker cover and my rear strut brace









with the engine bay drying the bonnet pins were fitted into the bonnet



that was all i managed to do saturday but work carried on on sunday;

the FRST fuel rail was mounted to the zetec spacer using some 'munson' rings from b&q and soldered them to a m8 thread







fitted the arp head bolts, head gasket, spacer plate and head.



the spacer plate was fitted as per ferridays instructions and was bonded on with a special compound designed for use in high pressure high temperature combustion engines, not convinced but ill try it



made a single wiper, cleaned and refitted scuttle panel, routed the wiring along the scuttle, the servo refitted, non-ABS master cylinder re-fitted and non-ABS brake lines fitted ( as my ABS didnt work on one wheel ) the power distribution block mounted and fuel filter mounted with freshly sprayed bracket and new bolts







fitted the zetec flywheel to the engine and the paddle clutch and pressure plate, de-gunked the gearbox and bolted that up.



A new CVH engine mount was modified and fitted and all new gearbox mounts fitted. the gearbox cradle cleaned and engine and box fitted







then added the TURBO touch to the rocker cover !



cheeRS
Andy

[jimmyesh]

Coming on a treat! Intrigued by the ferriday engineering head spacer sealing compound - will be interesting to see how good it is, I'm sure it will be as Ferriday are a good company

[Gazeddy]

loving the rocker cover

[MossyZS]

Top job!

Ernie told me about this on Friday night. I wondered why I haven't seem your car knocking around lately.

When its done I'll pop over and take a look... and a test drive

[recogniseman]

Nice work man! I'm watching this post closely as I am really keen to fit a 2l turbo to my mk4 feza. Good work getting the gf involved too.
Keep it up.

[garyhurn77]

nice k , what power do you think it'll make ?

[AndysFatRS]

garyhurn77 - not got a clue- as much as possible i hope

mossyzs - yeah mate no problem we'll have to sort something out, its not like you work far away really is it?

also just for a bit of info the 'buckets' for the injectors that i was talking about earlier are these;




right last update the engine was in, now next job was to fit the inlet manifold this was fitted using a gasket compound and the rocker cover drilled to fit the cross-over pipe, the cross-over pipe was bolted to the rocker cover with rubber spacers in between





the radiator and intercooler were then re-fitted into their new positons ( further forward ) and the pipework started be fitted.

this is the top boost hose that my mate knocked up




the engine wiring loom was stripped from its plastic mounts etc and re-wrapped with loom tape, with neccasary parts of the loom extended e.g IAT sensor and coil pack.

i fitted a set of Focus RS spark plugs as they are ideal for the pourpose as they are turbo friendly and fit directly to the zetec £21 trade from Ford





in order to fit the alternator the pulley has to be changed from the 'v-groove' pulley to the 'multi-v' pulley. simply swap the pulley off an zetec engined car onto your FRST alternator



top hose fitted and pipes connected



the driveshafts were refitted and hubs re-built gearbox oil added and the brakes bled.
the front bumper re-cut to clear the intercooler and was refitted along with the headlights and indicators





the back edge of the bonnet was raised in order to clear the cross-over pipe simply using a number of washers and all fluids were added and bled

and...

the car fired up!
and idled!
and revs!

and got washed! lol



after attaching a innovate wideband lambda probe the car was road tested and found to be running lean, as a temporary cure until mapping can be carried out the fuel pressure was turned up on the regulator and re-run. now within acceptable values.

at this point i must say the cams i have used are my Kent Cams N/A Fast road cams and apper to work fantastically with the turbo giving good low down power with minimal lag and brutal power from around 2800 revs.
on test low boost (10psi) the car is at least as quick as my cvh ever was when cammed and chipped running 16psi with beige injectors

on the return home all fluids were rechecked and no leaks/contamination was found. boost was then increased to 15psi where power is incredible with the car attempting to spin up in third on a straight road in the dry with pirelli Pzero nero tyres in near new condition.

CheeRS
Andy

[MossyZS]

Looking good today

[AndysFatRS]

just as a quick bit of info all my bills and reciepts added up to £423.48 hope this is a low enough budget to count as low budget, and if you are going to do a conversion you NEED an LSD.

[onslack]

congrats on getting it all working


that is one budget build

[demolition_man]

can you tell me more about the block breather please, like where you got it from and how and where you fitted it, ID etc

also i was wondering about the MAP sensor take off, is it in the rear of the zetec manifold? i didn't think the zetec used a MAP sensor? if i'm right then how did you make the take off.

thanks a lot

[nearly17]

Good work, Cossie rims on a fiesta look awesome.
Guessing it has a MAP sensor take off as its using FRST management?
as for the low budget ZT i will be following suit sometime soon with something similar for my Ka.

Aaron

[xr2imetalhead]

fair play mate looks like you have done a great job there

[HCS PIMP]

i want that engine wanna help me build a similar engine in my si ????

[fiestamk3.5]

any updates

[AndysFatRS]

UPDATE COMING SOON LADIES AND GENTLEMEN, WILL BE A GOOD ONE AS WELL AND ALL QUESTIONS WILL BE ANSWERED

[MattPym]

UPDATE COMING SOON LADIES AND GENTLEMEN, WILL BE A GOOD ONE AS WELL AND ALL QUESTIONS WILL BE ANSWERED

Even the meaning of life

[PUMARST]

Hi

very interesting topic. I have a 3 questions:

1) How thick is de-compression plate??
2) How many head gasket did you uesed?? If one where did you put it (between plate and head)
3) how strong this combination is?? Is it good for 14psi of boost or more??

[Ram]

nice thread and nice looking fez