Tuning the Zetec - Page 2
Last
on November 04 2024
Physical dimensions
Exacty how big is the Zetec engine? Well, you'd probably be surprised that it's not a great deal bigger than the X-flow. It is slightly taller, and longer, but not that much bigger.- Length: From the edge of the water pulley, to the edge of the cylinder head, the overall length is 500mm
- Height: From the bottom of the sump, to the top of the oil filler cap, the overall height is 600mm
- Width: From the edge of the oil pump filter mounting, to the front edge of the block, the width is 340mm
- Weight: 115Kgs (the Ford Pinto weighs approx 133Kg)
These pictures show the rebuilt 2.0 Zetec engine, ready to go back in to the Fiesta (September 2000).
Water pump warning !!
You need to be aware that the water pump on the Mondeo 2.0 Zetec engine is driven by a serpentine belt, and as such, rotates in a different direction to the Fiesta/Escort pump. The pumps look identical on the outside, however, inside, the impeller is a mirror image between models. This means that the water is still pumped through the engine in the same direction on the Mondeo and the Escort/Fiesta, despite the pumps turning in opposite directions. Therefore, you must make sure that the pump you use is designed for your installation. If you're using the serpentine belt drive, then use the Mondeo pump. If you're using the triangulated drive system (ie crank, water pump, alternator) then you must use the Escort/Fiesta pump. The outlet pipe on the Mondeo water pump, exits the front of the block at an angle, but the Fiesta/Escort pump outlet pipe exits in a straight line.For the later black top, or series 3 Zetec from the Focus, the solution is a reversed impellor from a place called Quicksilver Race Engines in the States, or an idler pulley made up to run the pulley in the same way as stock.
The two pictures below show the two different arrangements for driving the water pump. The serpentine system, as used on the Mondeo, and the triangulated system, as used on the Fiesta.
Key to pulleys: A = Alternator, W =Water Pump, C = Crankshaft
The Serpentine system
The Triangulated systemUse the correct grade of engine oil
Theres three different series of Zetec engines used in the UK. Series 1 was on the earliest Mondeo's, up to about the beginning of 1995. The S1 Zetec can be identified by "DOHC 16V" cast in to the rocker cover. These early engines are prone to sticking valves, especially at startup when the engine is cold. Later Series 2 engines have "16V Zetec" cast in to the rocker cover, and this engine does not suffer from the same problem.I had loads of problems with my Mondeo when I serviced her in June 1999. After spending two days at the Ford dealer in town, they diagnosed that the engine was running on the wrong grade of engine oil. I'd followed the guidelines in the handbook, and checked in the Haynes manual, and they both say to use 10W40 synthetic oil, which is what I used.
It transpires that the oil should be 5W30, which is thinner at low and high temperatures. My engine had been misfiring at startup, and stalling. This was due to sticking valves in the cylinder head, caused by the oil being too thick when cold. Top marks to my garage in spotting this. Black mark for the Ford and Haynes manuals.
Stranger still is that the pinking (pre-ignition) also seems to have been cured!
Have you checked which grade your engine is running?
Change the rod bolts
A particular weak point on the Zetec engines are the con-rod bolts. A lot of Zetec engines have lunched themselves because the rod-bolts have sheared under high load, and changing them is not a difficult or long job. You just need to buy a set of ARP rod bolts from Raceline or Burtons, and a new rubber sump gasket. Drain the oil from the sump, drop the sump off the engine, and replace the bolts, making sure to torque them up to the required level. Then replace the sump gasket, refit the sump, and refill the engine with oil.
