X/Flow to Zetec Conversion

[CaterBram]

I've managed to lay my hands on a Zetec Silvertop, 1.8l , originally from a Escort GTi which has been dyno'd on an engine test bed at 170BHP.

 

The engine already includes :-

The Engine

Ported Cylinder Head

the original gearbox, will swap to my original Type 9 - 5 Speed Quiafe

Alternator

Starter Motor

plug's & Leads

 

 

 

I think I will definatley need the following :-

Raceline - Inlet Manifold

Raceline - Inlet Manifold Securing Caphead Set

Raceline - Inlet Manifold Gasket

Raceline - Injection Mounting Stud

Raceline - Caterham Zetec engine mount set

Raceline - Exhaust primary set - Caterham

Raceline - 4-1 Stainless Steel Exhaust Collector

ARP Bolts

1 litre Swirl Pot

High Pressure Fuel Regulator

High Pressure Electric Fuel Pump

 

Possible Items If required

Clutch Release Bearing

Spigot Bearing

 

 

Now from reading various post's the 1.8l does not alway's need a full blown water rail etc but depending on how it look's once I get hold of it I may need.

 

Raceline - Water Rail

Raceline - Water Rail Fitting Kit

Raceline - Thermostat Housing Kit

Raceline - Heater Elbow Take-Off Blanking Plug

Raceline - Fan Switch

Raceline - Fan Switch Blanking Plug & Washer

Raceline - 90o Heater Elbow

 

 

I will be selling off once the engines been run in :-

Original Escort AT75 Gear box

Original Escort Inlet Manifold

Original Escort Exhaust Manifold

Complete X/Flow Engine & Twin Webbers

 

From what I can gather the clutch, water pump etc on the 1.8l is correct for a caterham installation.

 

Is there anything else i've forgotton ?

 

 

Q469 WET, 1990 1690 Xflow Long Cockpit in Ali except for the red bits. .CaterBram on Facebook

 

Edited by - CaterBram jnr on 28 May 2010 07:20:13

 

Edited by - Caterbram Jnr on 28 May 2010 09:07:31

 

Edited by - Caterbram Jnr on 28 May 2010 14:22:26

 

Edited by - Caterbram Jnr on 9 Oct 2010 17:46:37

[DohNut]

Alternator (or mounting kit to suit)

Flywheel / Starter Motor - they both need to match, I think there is one flywheel that fits the X-Flow starter motor.

 

 

[CaterBram]

Just checked it's got the original alternator & starter motor fitted, will the starter motor fit the T9 Bell housing ?

 

Q469 WET, 1990 1690 Xflow Long Cockpit in Ali except for the red bits. .CaterBram on Facebook

 

Edited by - CaterBram Jnr on 27 May 2010 07:07:10

[Molecular--Bob]

You can use the 1.8 zetec flywheel, but may have problems getting a starter to fit if you use the raceline sump. If you use the Dunnell/Scholar cut and baffled one then a LUCAS LRS707 (or equivalent) will work. Pretty sure the Zetec one is not going to fit.

 

Retro Ford do a cheaper Alternator mount and i think it will allow you to reuse the crossflow alternator. There is a clutch combo that will bolt to this flywheel without alteration, but some prefer to have them redrilled (retroford again) to allow the fitting of uprated pinto clutches.

 

I am planning on using the original ford stat housing as it allows the engine to run as ford intended. May not look as nice but it should keep the engine happy.

 

A helpful non-caterham forum is Turbosport, they are mostly about old fords, but there is a fair bit of knowledge there about things zetec.

[Klunk]

Have you already bought/fitted the injection fuel tank/pump/extra fuel line etc?

 

Giles

[CaterBram]

I'm already on an electric fuel pump with as far as i'm aware a standard fuel tank

 

Is this suitable or is there something special about an injection fuel tank / pump / extra fuel line ?

 

 

 

Q469 WET, 1990 1690 Xflow Long Cockpit in Ali except for the red bits. .CaterBram on Facebook

[jonboylaw]

In injection tank is sealed and has a return pipe. The fuel is pumped under much higher pressure through the filter, regulator to the fuel rail and then the un used fuel is returned to the tank.

 

Looks like you need to budget for a new injection tank.

 

 

 

Jonathan

 

My Flickr

 

-----------------------------------

95% there :)

 

92 Supersprint, Ford LSD LA, RK AX Crossflow.

 

[Klunk]

The cost of the tank and pump is another £370 from Caterham. You can run an external swirl pot system instead which will cost you about £150 for the swirl pot and high pressure pump, but you still have to put a return pipe into your existing tank and run both a low & high pressure pump which means you need an additional 12v supply wiring in. Webcon also do a unit that can be fitted into the top of the tank but I'm not sure how easy that is to fit, or if there is enough clearance beneath the boot floor.

 

On numerous occasions I have thought about moving to fuel injection but for the mileage I do a year I struggle to justify it.

 

At the end of the day it all depends on the size of your wallet and time. Right now I'm in short supply on both counts 😬

 

Giles

 

 

 

 

 

Edited by - Klunk on 27 May 2010 19:07:36

[Molecular--Bob]

With a re-jet/re-choke, your crossflow webers will work well with this engine (assuming you have 40's, crossflow '45s not so good due to missmatched progression drillings). You will need an ecu such as megajolt to do the ignition side. I think you can use all of the zetec clutch but will need a specific CRB to get it to work, may also give a bit of a heavy feel to the clutch.

 

Cheapest option for sumps is theTiger cast one, but it isn't baffled, so strongly advised to modify it to baffle the pickup (not seen this used in a Caterham but cant see why it wouldn't work).

[CaterBram]

I've got 40 Webber's but the engine already has an ECU & Throttle bodies with it, thought i'd take the plunge in one go so to speak to convert to injection,.

 

Is the clutch release bearing the same as the MT75 Gearbox clutch release bearing fitted in the existing gearbox ?

 

I'll have a look at the Tiger cast one and work out if it's worth the saving over an already baffled one.

 

Q469 WET, 1990 1690 Xflow Long Cockpit in Ali except for the red bits. .CaterBram on Facebook

[Klunk]

Sorry misread your post. The CRB for a type 9 is different from the MT75 which often has a 20mm(approx) spacer glued to the front. Westfield used to use this with a CVH clutch (can't remember the car off hand) and the standard 1.8 flywheel as its considerably lighter. I'd go for as close to the original Sierra set up as possible i.e. pinto clutch & CRB and get modified flywheel to suit.

 

Giles

 

Edited by - Klunk on 28 May 2010 09:09:54

[ChrisHawkins]

With you changing gearboxes from Type 2 to Type 9 I assume you have the 2nd gearbox mount already on your chassis or a conversion kit?

 

If you need clutch, clutch bearing, flywheel or starter help then speak to Burton power as they were very helpful identifying what i had and what I needed

 

Chris

 

K93 AMJ

 

Edited by - ChrisHawkins on 28 May 2010 09:05:35

[CaterBram]

I'm already running a quaife type 9 5 speed gear box on the X/Flow and that will be retained and used with the Zetec.

 

I'll have to do so digging regard the clutch bearing.

 

Q469 WET, 1990 1690 Xflow Long Cockpit in Ali except for the red bits. .CaterBram on Facebook

 

Edited by - CaterBram Jnr on 28 May 2010 09:10:43

[Klunk]

I must get quicker with my editing. (Don't know whether you've seen my updated post )

 

If you give me 'til after the weekend I should be able to tell you exactly, as I fetching my engine out of my Sylva Stylus this weekend and that has the zetec/type 9 combo in it.

 

Giles

[CaterBram]

Cheer's Giles,

 

just read the modified post, won't be putting the engine / gearbox combination together until begining of July hopefully so there's no great rush, but any information would be appreciated.

 

Regards

 

Chris Bramall

 

Q469 WET, 1990 1690 Xflow Long Cockpit in Ali except for the red bits. .CaterBram on Facebook

[Jaseb]

From memory you'll need a spigot bush too

[CaterBram]

I'll be able to check this against the shaft size on the original gearbox when compared to my type 9.

 

 

 

Q469 WET, 1990 1690 Xflow Long Cockpit in Ali except for the red bits. .CaterBram on Facebook