Engine Swap

[Sook]

Now it's the winter and the chances to take the car out are limited I've started daydreaming about projects. My car currently has a 1.7 XFlow in it, but it's getting a bit long in the tooth and it needs a rebuild. Now, I'm wondering how difficult it would be to swap it for something like a 1.8 Zetec, which should hopefully give me better performance, better fuel consumption and a reduction in the amount of exhaust entering the cockpit!

Apart from (presumably) requiring new engine mounting points, does anyone know of any other difficulties with fitting a Zetec in a Stylus?

[alecmartin19]

had no problems fittin a zetec in my stylus. just beware of the splines on the gearbox shaft and the splines on the clutch plate. if you use a type 9 box you will have a large diameter shaft and some zetec clutches are for small diameter shafts as on escorts and orions. you will need a mondeo clutch from a 2 litre. thats assuming its going to be a zetec E with a silver cam cover. i'm not sure about the other engines but it may be worth checking!

[Werner Van Loock]

Make sure you get a escort/orion (silvertop)zetec for a number of reasons (sump, waterpump, ...)

Only thing to change then is a alternator relocation with different belt, some induction (original, Throttlebodies or carbs) and some ignition/ECU (depending of carbs or injection)
And change the clutch plate and cover for a early mondeo 1.6/1.8 with 23 splines so it fits inside the type9 bellhouse and accepts the type9 drive shaft.

A CT133 release bearing if I'm right and a spigot bearing. And that's about it. If you buy a mondeo lump, then you have to change a lot, unless you go 2L that was only used in the mondeo.

A startermotor from a 1.8CVH siearra or 2.0 DOHC sierra is needed.

Thats it i guess, unless I forgot something. Rob? You got zetec.

[Sook]

Thanks guys, I'm going to have a bit of a search around and see how much it's going to cost me! Seeing as buying a house at the moment looks like it's out of the question, it'll give me something to save up for!

[stylussprinter]

It's a doddle putting a Zetec in but there's no point in using the 1.8 when the same dimensions will give you 2lt . More torque , easier to drive even in standard form. Contact Dunnell/Raceline regarding correct clutch etc for the 23 spline type 9 box . If ever you consider boosting the bhp you'll wish you'd fitted a decent clutch as the standard one wont last long under spirited use. If you fit a Raceline wet sump you'll need a specific crossflow starter. Some , although not listed as different , are shorter than others and it's the short one you need. If you make the engine mounts yourself , then make the passenger side mount with a 4mm webbed engine plate or it will break The stock originals were 2.5mm which was fine on the drivers side as it takes little stress. Also you need to use the 1.8lt water pump on the 2lt to make sure it goes the right way because only needing the pump and alternator makes the belt drive different.(no power steering etc) Good idea to use a larger alternator pulley as rev's will make it charge too hard

Rob

[Schrodinger]

When I built my Tiger Cat I started with a Pinto and then converted to a 1.8l Zetec with 2.0l cams, with home made throttle bodies (converted DCOE 40s) and it produced 149 BHP at the flywheel with an Emerald ECU.
Along with the engine mounts and modified cooling pipes I also had to get a set of headers, the spigot bearing, I had a 2.0l flywheel which I had lightened and modified to accept a 2.0l Pinto clutch, starter from a CVH Sierra, vw golf GTI fuel pump and accumulator (swirl pot) supplied by the low pressure pump I already had and had to put in a return fuel line which in my case required a new fuel tank as well. Oh and a shortened sump which may not be required in the stylus though.
Have a look in
http://www.toyne.org.uk/zetec-cat.html
which gives an insight into the various zetec engines and part numbers, plumbing etc.

I did also write an article on the swap/TBs for the local Tiger owners newsletter if anybody is interested.