As iv mentiond am starting a new project 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

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

good luck. what car's it going in?

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

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

Good luck daz will be watching how this goes with alot of interest.

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

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
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

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

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 )

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

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?

It'll be a trackcar.
With the ECU am getting standard 2.0 settings so that I can tinker with them.
I'll get some pics up when I recieve the parts

Well I have paid for my pistons at a very cheap price 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

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.

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!

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.

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

Correct.
Well, the Focus RS Duratec engine is based on a zetec so I am using some parts off that (Sparkplugs, Head gasket etc).

chavtastic to the rescue.

Or at least thats who i think dazza got the pistons from, if it is they are C20LET pistons.

They ahve a compression ration of 8.5 to 9:1.

nice and low for more boost.

Yep thats right
Correct compression ratio that I need too

sorry i miss reada arrticale on a mondeo that had been turboed . i thourght he had bourght a zetec turbo but it was a yb cossie unit.

Had a litttle clean but I want to strip the turbo as it has a little play in the shaft. Heres a few pics of some of the bits I have so far (Still awaiting my pistons and manifold)







This is how it will sit once fitted


This is the oil return on the sump


At the bottom you can see the oil return, and at the top you can see the sump plug (Oil return is on the front of the sump)


Piece of induction hose, goes from the TB


A few 90degree hoses used for the cooler

Bailey DumpValve

Had a thort the other day dazza. Wont u need a custom HG??

Think when i get my next car i wont sell the scort but ill take it off the road and turn it into my fun car.


Do u know if the 1.8 and 2.0 ZETEC are the same size block. Ive heard that they are identical except the 2.0 is bored out further,apparently the water and oilways are the same,same place,same size

Whats a HG?

The blocks are the same size yes mate, its on the internals that alter the cubic capacity mate, oh and sadly the fiesta wont return to the roads (I dont think anyway)

head gasket mate,sorry,shudda mentioned that.

wont part of the gasket hang into the cylinders?therefore needing a gasket of the exact bore your new cylinders are gonna be.

Sorry to copy u man but it looks like i may do the same when i get the new car,cos it seems quite cheap after all,u gonna fully strip the car? go on,u know u want to.

The headgasket will be off a Focus RS, there a 2.0 duratec (Zetec based) so are an exact fit. All series 3 zetec headgaskets aslong as there triple layed are the same as the RS gasket

I wouldnt say there cheap to do, but in terms of turboing an engine they are - If you get me

I know a friend selling a virtually brand new one for £1700 if your interested

unfortunately i wudnt consider turboing mine for clsoe to 2 years mate,the RS gasket may be an exact fit on a 2.0 ZETEC but urs gonna be a 2.05 so u sure itll still fit?

Yep it'll defo fit mate no need to worry. My mates engine uses the same pistons/head gasket etc but he classes his as a 2.1

The std RS gasket will be fine on a slight overbore as it will still fit flush with where it will sit on the head as this wont have changed.

There may be a slight overlap at the top of the cylinders, but not enough to cause any problems

Just realised I havnt put the pics up of my pistons and manifold after they arrived. No other items have been bought since.

Bit blurry but he's a cleaned up piston


Side on view of the piston, needs a set of rings. Note: Needs a small mod to fit to the zetec conrods


Brand new ERST manifold (Someone monce paid £80 for it, lets say I got it for no were near that)


How it will sit once all bolted together. I am getting rid of the exhaust elbow in favor of one from a SAAB, this will allow me enough room for the downpipe otherwise the radiator will be in the way.

had a gander into this meself to see if its a viable option one day.Seems so,but there is so much to research,the spec u choose today will cost a lot and if u dont uprate certain parts now u will have to do them when u get bored with your current power level.Think id plan a 300BHP build.
What drivetrain u using dazza.And how u gonna mate the pistons to ur small ends?the website i checked mentioned custom rods

The standard conrods are good for 300bhp but after that your pushing it, the mod is relativly simple as its only a case of swapping gudgeon pins and then the circlip. ARP rods bolts are needed and while am doing that i'll use a new set of shells not to mention the new piston rings.

Using the C20LET pistons I will have a CR of 7.4:1 but my main concern is that its reliable hence all the new parts being added. Even tho I have quoted 230bhp this is an under estimate as I will get this minimum, 300bhp is the target am working for.

Since the blocks being bored to accept a 86mm piston, it changes the cubic capacity from 1998cc to 2048ccish which makes it a 2.1 engine rather than 2.0 (Was a concern as I will not be able to run in the 1300 to 2000 races).

The Transmission is still in debate (with myself ) but its a choice between the IB5, the MTX75 box or the S2 turbo box (contains an LSD) which atm is the winner, also using a 4/6 paddle clutch depending on certain things.

Dont kid yourself, its not cheap to do and the info on the net is not all thats needed so you cant simply print off a copy and hey-presto everyones got a ZT so just bare that in mind bud

Apparently a standard IB5 is seriously poor for use on ZTs,needs worked to make it safe,the MTX im not sure of,i hear its stronger so it may handle it,but an S2 box deffo seems the way to go. Maybe a worked IB5 with quaiffe ATB (the famous focus RS diff)wud be the ultimate tho.Those quaiffe ATBs are only 500 pound (which i think is quite cheap for "the best differential")

The gearbox man does decent S2 boxs with quaife diff hence why there the best and the likely winner. IB5 is weak and even tho I would get a good ratio, like iv said am after reliability so would be a no no. MTX75 is stronger and has a higher topend, but i'll loose my close ratio and can be a mare to fit.

I was getting a stage 2 CTS box cheap (done 2k miles) but the guy failed to get back to me, so I might dig his number out again.

My focus is on the engine as its early days hence why am not too bothered about boxs at this point

Good luck with this. More head scratching to come I bet!