Budget Cortina Zetec install
Discussion
OK, I have a 1980 Cortina 1.6 and wanted to know how much it would cost to install a 2.0 Zetec. I already have a 2.0 Mondeo with a silver top for use as a donor. I can make my own engine mounts. There is an inlet manifold available to utilise the 2.0 Webber 32/36 Carb that is fitted to the Cortina. I have been told that you can use the Fiesta Mk3 ignition system but know very little about how good it is in this application or how to wire it in. I also know that there are issues with the cooling system as well. I know the gearbox will bolt to the engine but I am unsure of how to make the clutch work.
I want to do this on a very tight budget but want a reliable and good running engine with more power.
Richie
I want to do this on a very tight budget but want a reliable and good running engine with more power.
Richie
Edited by richies2.0gl on Saturday 14th November 22:37
The Ford ESC ignition system has been used by many people for Zetec conversions, though it comes from a small capacity 8v CHV engine so the ignition map is never going to be optimal for the Zetec. It is a cheap way of getting a Zetec running though.
Most of the inlet manifolds for use with the downdraught Weber seem to be directed towards banger racing applications. The ones I have seen have been terrible in terms of design, you'd have to really try to make something flow worse. It's possible to use a 1.8 CVH manifold with an adapter plate. Retaining the EFI would of course be the best solution, and remove the ignition issues at the same time...
Zetec will bolt up to the Cortina box, but don't forget to fit a spigot bearing to the end of the crank. There are a couple of budget options with the clutch; you can use an early Mk1 1.8 Mondeo 220mm clutch kit (Ford cover 93BG7563AA, Ford plate 93BG 7550AA) with a Ford Capri Mk1 thrust bearing (QH part CCT133), or others have had the Zetec flywheel re-drilled for a Pinto clutch which allows you to keep the original Pinto clutch parts.
You will need a different starter motor, the one from a 1.8CVH Sierra is the usual candidate.
The water pump on a Mondeo engine rotates the wrong way for a simple RWD install, but since you are using the silvertop engine, you can simply fit the waterpump from a 1.8L Escort and the problem is gone.
Beware the Raceline water rail, it mounts the thermostat much further from the head than Ford intended and numerous people have experienced cooling problems. The Retroford water rail is a much better design.
Most of the inlet manifolds for use with the downdraught Weber seem to be directed towards banger racing applications. The ones I have seen have been terrible in terms of design, you'd have to really try to make something flow worse. It's possible to use a 1.8 CVH manifold with an adapter plate. Retaining the EFI would of course be the best solution, and remove the ignition issues at the same time...
Zetec will bolt up to the Cortina box, but don't forget to fit a spigot bearing to the end of the crank. There are a couple of budget options with the clutch; you can use an early Mk1 1.8 Mondeo 220mm clutch kit (Ford cover 93BG7563AA, Ford plate 93BG 7550AA) with a Ford Capri Mk1 thrust bearing (QH part CCT133), or others have had the Zetec flywheel re-drilled for a Pinto clutch which allows you to keep the original Pinto clutch parts.
You will need a different starter motor, the one from a 1.8CVH Sierra is the usual candidate.
The water pump on a Mondeo engine rotates the wrong way for a simple RWD install, but since you are using the silvertop engine, you can simply fit the waterpump from a 1.8L Escort and the problem is gone.
Beware the Raceline water rail, it mounts the thermostat much further from the head than Ford intended and numerous people have experienced cooling problems. The Retroford water rail is a much better design.
Edited by Mr2Mike on Sunday 15th November 18:11
Wow, thats everything I asked for! Thank you. So, if I change the water pump on the Zetec does that mean I dont have to buy the coolant rail?
This sounds very feasable to me and has given me the enthusiasm to take this on (next year when I have some extra time). In the mean time I will get everything I need for the conversion.
This sounds very feasable to me and has given me the enthusiasm to take this on (next year when I have some extra time). In the mean time I will get everything I need for the conversion.
The waterpump issue arises because the Mondeo has a power steering pump and possibly an aircon pump mounted on the right hand side of the engine, as you look toward the crank pulley. In order to be able to route the serpentine belt to drive all the components with adequate "wrap" on the pulleys, the waterpump had to be driven from the back (smooth side) of the belt, and therefore rotates backwards. When you stick the Zetec into a kit car or older car, you usually ditch the aircon and power steering pump, which means there is no easy way to route the belt over the waterpump unless you drive it from the ribbed side. This is what the escort pump allows you to do.
The thermostat location is another issue altogether; the thermostat housing is a pretty chunk item mounted right at the back of the head, where it often causes clearance issues with the bulkhead on a RWD installation. The water rail overcomes these problems by having a very low profile at the rear of the engine where it bolts to the head, and routes the coolant right back to the front where your radiator is (probably!). They aren't cheap however, and may not be required if you have adequate clearance at the back.
The thermostat location is another issue altogether; the thermostat housing is a pretty chunk item mounted right at the back of the head, where it often causes clearance issues with the bulkhead on a RWD installation. The water rail overcomes these problems by having a very low profile at the rear of the engine where it bolts to the head, and routes the coolant right back to the front where your radiator is (probably!). They aren't cheap however, and may not be required if you have adequate clearance at the back.
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