Sumps

 

The sump on a ZETEC is in affect just an alloy box which will get in the way for RWD conversions.  If you are planning on a FWD conversion (ie MK1 Fiesta) then use an Escort ZETEC sump as this is close enough to the original CVH/Valencia sump shape.  Dunnell do a combined sump/engine mounts which is expensive, but I am lead to believe will mount the engine in a better position (further back, aiding weight distribution).  Martin Paynter (The Escort Agency) sells sumps (including pick-up, dipstick and gasket) for RWD conversions at £135.  Dave Colledge (07813436514) also sells them for the same price, in fact it's him that makes them.  All the RetroFord conversion parts come with all the fittings, gaskets etc which helps.

Beware some sumps on the market require the steering rack to be lowered, not very good for your handling!

 

It may be worth trying a Sierra 1.8 CVH sump/pick up pipe if you are on a budget, but it will need modifying.  The only problem you will have is the location of the dipstick as it  will clash with the engine mounts/manifolds.  Many thanks to Paul Ludlow for e-mailing me these pictures for converting the CVH sump.

 

 

The green lines show what you need to remove to clear the crossmember.

 

 

The green lines show were you will need to make 'big wings' to hold the oil.

Engine mounts

Raceline used to sell adapted X/flow mounts for ZETEC conversions, however, some people believe this will mount the engine to far forward and possibly mess up the balance of the car. Raceline are considering remanufacturing these mounts again because demand has grown.  Again the Dunnell system (see above) seems the best but at £350 + vat, it should be. 

Martin Payner (The Escort Agency) and Dave Colledge (Retroford) sell zinc plated engine mounts at £70 a pair to suit standard and World Cup Xmembers.  I have used their World Cup Xmember mounts and they are spot on, although despite the zinc coating I still gave them 2 coats of hammerite to make sure they didn't rust.

 

RetroFord mounts

Water Rail

 

As the ZETEC was only ever desined to be used in front wheel drive applications the thermostat/housing is in completly the wrong place for a RWD car and sits at the back of the engine.  In order to get this to fit you need to remove the thermostat and either use a water rail, or re-drill the block and use a smaller thermostat housing such as the pinto one.

RetroFord and Raceline do water rails that not only solve the thermostat housing problem, but also move the outlet to the front of the car so only a normal hose is needed to conect it to the radiator.  the RetroFord also has an off take for the heater matrix which doubles as a thermostat bypass system.

Alternator Mounts

 

I do not know exactly whether is is essential to move the alternator or not, but I have never seen a RWD ZETEC in any car where it has not been done.  All the usual places sell kit to move the alternator to the other side of the engine, beneath the carbs/throttle bodies.

The later ZETECs alternator's were wired through the ECU so that the rate of charge changed based on what was needed, rather than the number of revs.  These alternators will not work in the old way so you will need an alternator from an earlier model, or different car.

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