WikiWirral Share a Little Learn a Lot about your Wirral
Forum Stats
12137 Members
65 Forums
72400 Topics
976204 Posts
60 posts in the last 24hrs
Max Online: 7831 @ 8th Apr 2013 4:18pm
Who's Online - Click Me
79 registered (alan128, 11 invisible), 1532 Guests and 265 Spiders online.
Key: Admin, Global Mod, Mod
Social Media : Follow Us


(Views 7days)This Weeks Most Read
Vet help 573
Another Big Waste Fire in Liverpool. 521
Talk Talk Security Breach 435
Anyone Read Chinese Writing 368
Another tree down on Arrowe park Road? 288
Mobile mechanic needed to fit a wishbone 259
That was kept a bit quiet? 245
RIP Peter Vaughan 193
Game shocking prices!!! 164
Cowhouses 161
New General Forums
Lib/dems rule the day
by JimmyG
2nd Dec 2016 10:59pm
Daft funny joke
by venice
2nd Dec 2016 5:54pm
We dont learn much.
by venice
1st Dec 2016 9:22pm
Freegle
by venice
1st Dec 2016 6:36pm
New Wirral History
Cowhouses
by Norton
Yesterday at 03:34 PM
Name help
by Paternoster21
3rd Dec 2016 8:03am
HMT Lancastria
by granny
2nd Dec 2016 11:38pm
Cubitts Holland and Hannen
by fish5133
27th Nov 2016 5:38pm
Fire station
by chris7777
22nd Nov 2016 12:24pm
Forum Tips
Photo Gallery Forums
fireworks on the Mersey last night
Hadlow train station
Topic Replies
Cowhouses
by fish5133
Today at 02:23 AM
Virgin broadband
by fish5133
Today at 02:18 AM
Iphone 5s, Grey, near mint condition, 50
by _Steve_
Yesterday at 09:59 PM
Merseyrail
by TheComputerLab
Yesterday at 09:14 PM
Steel frame with wheels
by anniebo28
Yesterday at 08:06 PM
Mountain bike carrera Vulcan 100 excellent cond
by TheComputerLab
Yesterday at 03:57 PM
Offline Monday
by Mark
Yesterday at 12:13 PM
Anyone Read Chinese Writing
by Tranquil
Yesterday at 01:44 AM
Talk Talk Security Breach
by eddtheduck
9th Dec 2016 10:46pm
December
M Tu W Th F Sa Su
1 2 3 4
5 6 7 8 9 10 11
12 13 14 15 16 17 18
19 20 21 22 23 24 25
26 27 28 29 30 31
Recent Posts : What's On ?
Wirral TUC Meeting re Update on Wallasey CLP Suspe
by RUDEBOX
30th Nov 2016 9:16pm
World Aids Day Event 2016. Liverpool
by RUDEBOX
30th Nov 2016 9:05pm
Page 1 of 3 1 2 3 >
Topic Options
Rate This Topic
#128674 - 17th Feb 2006 8:09pm 2.0 Zetec Turbo build
Dazza Offline
Forum Master

Registered: 10th Nov 2003
Posts: 2899
Loc: Birkenhead
As iv mentiond am starting a new project laugh This will be a LONG project so dont expect weekly updates. This project will be how I am building it as there are many different ways using many different parts.

If turbo'ing an engine in general terms it WILL cost a fortune, however for a Zetec turbo its not as bad since most Ford engine parts are compatible and interchangable which is always a good thing smile

So far I have the turbo, escort turbo manifold and a zetec sump thats been modifiyd.

By using the escort turbo (ERST) manifold the ports match those on the zetec head but unfortunetly the studs do not so the head needs drilling/tapping to accept the new studs.

For the turbo am using the T3 garret turbo (From a ERST) as I could use a bigger/small turbo but am after the finished result and not power upgrades at this point, once its finished then I can look into it.

The zetec sump is basicly standard except an oil return valve has been welded in above fluid level, this is for the turbo oil return but I will need to sort an oil feed to it at a later date (The block needs a new feed tapping into it).


Poor picture from eBay of my brand new ERST manifold (Ford no longer produce them).


Bad picture of the turbo and I dont currently have a pic of the sump
_________________________
My website: www.TeamFord.co.uk

Top
AutoWirral : Advertising
Click me for more Information......

* * * WikiWirral - Advertising Forum * * *
Now Advertise with WikiWirral.
WikiWirral stats 35,000 Page Views a Day +500 Search Engines.. Click Me
#128675 - 17th Feb 2006 10:01pm Re: 2.0 Zetec Turbo build
lazy_ben Offline
Wise One

Registered: 5th Jan 2004
Posts: 868
Loc: Moreton
good luck. what car's it going in?
_________________________


new msn/email: bena3turbo@hotmail.com

Top
#128676 - 17th Feb 2006 10:03pm Re: 2.0 Zetec Turbo build
Dazza Offline
Forum Master

Registered: 10th Nov 2003
Posts: 2899
Loc: Birkenhead
Eventually in the Fiesta, I'll be using another 2.0 engine as a base. Then I can enjoy the fiesta how it is until the engines finished laugh
_________________________
My website: www.TeamFord.co.uk

Top
#128677 - 17th Feb 2006 10:38pm Re: 2.0 Zetec Turbo build
Mark Online   Reading


Wiki Master

Registered: 9th Nov 2003
Posts: 20966
Loc: Wirral
This will be great to follow,
hopefully you will also let us in on some of the mistakes along the way if any...

At the end your going to have an awesome topic.

Good Luck smile
_________________________
My Avatar images are all from the Wirral Gallery.Click Me
Wow Wirral History is coming along Great! Wirral History

we get +200 new members a month now smile

Top
#128678 - 18th Feb 2006 9:34am Re: 2.0 Zetec Turbo build
spinking Offline
Forum Veteran

Registered: 11th May 2004
Posts: 5093
Loc: Happy Home
Good luck daz will be watching how this goes with alot of interest.
_________________________
drifting drifting and yet more skidding

Top
#128679 - 21st Feb 2006 9:17pm Re: 2.0 Zetec Turbo build
Dazza Offline
Forum Master

Registered: 10th Nov 2003
Posts: 2899
Loc: Birkenhead
Exhaust manifold should be arriving 2mrw and the turbo, sump, hoses and DV are all being collected on saturday.

When doing a zetec turbo conversion you have the problem of lowering the compression ratio, there are a few ways of doing this and despite my other post about xe pistons, I have found the following to be ideal - C20LET pistons.

C20LET pistons are found in the calibra and astra turbo. They are just under 86mm width so a very slight rebore will be needed changing the engines cubic capacity (cc) from 1998cc to 2045cc. I have sourced/sourcing a set that may require a slight skim on the crowns but nothing to worry about - Plus am getting them ver very cheap wink

At this point I havnt mentiond the managment issues of a zetec turbo.

The standard ECU cannot run a turbo (cant allow for boost etc), I am NOT doing the usual route of using a FRST inlet simply because, a 2.0 using a 1.6 inlet is restrictive! I shall be using my current favourite - The focus inlet wink
Since NO FRST/ERST parts are being used bar the manifold/turbo combo I am not using the turbo managment (OFAC/OFAB ecu).

Because of the above aftermarket managment will have to be used, and am going to use MegaSquirt. Once fitted I will be able to custom map the ECU myself (think of the money saved) and the ECU can do a host of things such as launch control and progressive NOS. I am aware that its not an easy thing to do (I know it'll not be as good as the reputable company that specialises in it) but it is all I require.

Good News about the pistons tho laugh
_________________________
My website: www.TeamFord.co.uk

Top
#128680 - 21st Feb 2006 10:06pm Re: 2.0 Zetec Turbo build
scoop Offline
Wiki Addict

Registered: 18th Nov 2004
Posts: 7238
Loc: Leuchars
lookin cool dazza,gonna be a long job?and uve already got a fair few bits already.Mapping it yourself will be a challenge but good luck and if u manage it it'll be much kudos to u.great News on the pistons,but are the small ends of the rods the same between the zetec and the vaux engine?

cant wait to see pics of the engine goin together
_________________________

Top
#128681 - 21st Feb 2006 10:09pm Re: 2.0 Zetec Turbo build
Dazza Offline
Forum Master

Registered: 10th Nov 2003
Posts: 2899
Loc: Birkenhead
Even tho iv sourced parts quite quickly am still expecting a long build time.
With the mapping, the ECU comes with the correct programs and theres enough data on the net to help me do it, it can plug in to a laptop and you live map it (Kinda like the fast and the furious tease )

The rods are not a problem, but the gudgeon pin needs to be modifiyed to allow fitment of the LET pistons, its a small job or so am told.

Dont worry I'll get enough pics up smile
_________________________
My website: www.TeamFord.co.uk

Top
#128682 - 21st Feb 2006 10:27pm Re: 2.0 Zetec Turbo build
scoop Offline
Wiki Addict

Registered: 18th Nov 2004
Posts: 7238
Loc: Leuchars
So the ECU wont leave u completely in the lurch and make it run lean as **** on startup then?itll have a rough idea of what to do,thats good.How u gonna insure this beast man?
_________________________

Top
#128683 - 22nd Feb 2006 12:38am Re: 2.0 Zetec Turbo build
Dazza Offline
Forum Master

Registered: 10th Nov 2003
Posts: 2899
Loc: Birkenhead
It'll be a trackcar.
With the ECU am getting standard 2.0 settings so that I can tinker with them. smile
I'll get some pics up when I recieve the parts
_________________________
My website: www.TeamFord.co.uk

Top
#128684 - 23rd Feb 2006 1:31am Re: 2.0 Zetec Turbo build
Dazza Offline
Forum Master

Registered: 10th Nov 2003
Posts: 2899
Loc: Birkenhead
Well I have paid for my pistons at a very cheap price wink Below is a pic I was sent of one of them, as you can see if has valve cutouts and a domed crown, this is what alters the compression.



When all my bits and bobs arrive I'll post some decent pics up. The pistons could do with a clean up. Onwards and upwards laugh
_________________________
My website: www.TeamFord.co.uk

Top
#128685 - 23rd Feb 2006 6:43pm Re: 2.0 Zetec Turbo build
Johnny Alan Offline
Forum Addict

Registered: 15th Sep 2004
Posts: 2082
Loc: wirral
What you can also do is drill holes in the conrod and glue small pieces of cork into the holes this makes a lighter conrod and keeps the secondary compresion the same, overall make it more revvy. Dnt drill to big of a hole so it snaps though.
_________________________
Zoom,Beep,Zoom,Beep,Zoom,Beep.....................

Top
#128686 - 23rd Feb 2006 9:15pm Re: 2.0 Zetec Turbo build
Dazza Offline
Forum Master

Registered: 10th Nov 2003
Posts: 2899
Loc: Birkenhead
eek
Does this actually work and work reliably? I wont do it on mine as of the pressure build up etc but Iv not heard that method!
_________________________
My website: www.TeamFord.co.uk

Top
#128687 - 26th Feb 2006 5:15pm Re: 2.0 Zetec Turbo build
robbie Offline
Enthusiast

Registered: 1st Mar 2004
Posts: 187
Loc: BROMBOROUGH
dazza just seen the topic good luck and ile be watchin very carefully but wouldnt it be easier just gettin a 2.0 tubro unit out of an older mondeo or is it so you can build yourself. think
_________________________

Top
#128688 - 26th Feb 2006 6:21pm Re: 2.0 Zetec Turbo build
scoop Offline
Wiki Addict

Registered: 18th Nov 2004
Posts: 7238
Loc: Leuchars
2.0 turbo zetec is not an existing engine unfortunately robbie.the only thing similar to this would be to get a FRST engine.and theyre too small,so if ur gonna go through some trouble to get ur turbo'd fez,u may aswell start with a zetec
_________________________

Top
Page 1 of 3 1 2 3 >

Moderator:  StuyMac 
Random Wirral Images

Click to View Topic.
Newest Topics
Virgin broadband
by corona
Yesterday at 05:20 PM
Cowhouses
by Norton
Yesterday at 03:34 PM
Merseyrail
by ambersmum
Yesterday at 02:52 PM
Offline Monday
by Mark
Yesterday at 12:13 PM
Anyone Read Chinese Writing
by Tranquil
9th Dec 2016 3:47pm
For Sale & Free
Steel frame with wheels
by anniebo28
Yesterday at 08:06 PM
Mountain bike carrera Vulcan 100 excellent cond
by TheComputerLab
Yesterday at 03:57 PM
Micro desktop PC
by anniebo28
8th Dec 2016 2:24pm
Iphone 5s, Grey, near mint condition, 50
by anniebo28
7th Dec 2016 7:40pm
Roberts Concerto 2 CD Player For Visually Impaired
by Tranquil
6th Dec 2016 10:05pm
Featured Member
Registered: 20th Feb 2015
Posts: 47
Newest Members
lucyw, BarbaraL, SherryLover, missyb, DavidSharpe
12137 Registered Users
Today's Birthdays
No Birthdays
New Wirral Info
Anyone Read Chinese Writing
by Tranquil
9th Dec 2016 3:47pm
Gymnastics coaches needed.
by margy
3rd Dec 2016 9:28pm
Wirral Globe
by locomotive
1st Dec 2016 6:25pm
Wirral TUC Meeting re Update on Wallasey CLP Suspe
by RUDEBOX
30th Nov 2016 9:16pm
World Aids Day Event 2016. Liverpool
by RUDEBOX
30th Nov 2016 9:05pm
News : New Topics
Geert Wilders
by fish5133
9th Dec 2016 2:44pm
RIP Peter Vaughan
by diggingdeeper
7th Dec 2016 4:22am
That was kept a bit quiet?
by venice
6th Dec 2016 11:25am
Another tree down on Arrowe park Road?
by Davefabo
6th Dec 2016 11:08am
Bunchems Xmas present warning
by venice
6th Dec 2016 9:28am
New Enthusiast Forums
Virgin broadband
by corona
Yesterday at 05:20 PM
Talk Talk Security Breach
by fish5133
7th Dec 2016 6:19pm
Mobile mechanic needed to fit a wishbone
by anniebo28
6th Dec 2016 7:13pm
Vet help
by colin86
6th Dec 2016 6:25pm
Game shocking prices!!!
by eddtheduck
5th Dec 2016 4:55pm
(Views 24hrs)Trending Newest Topics
Cowhouses 161
Virgin broadband 140
Steel frame with wheels 44
Merseyrail 28
Offline Monday 18
Wirral Sunrise Sunset
Sunrise Sun 8:19am
Sunset Sun 3:52pm
Local Time Sun 5:49am
WikiWirral Can . . . .