Zetec information and development

[Cobra289]

Hi,
We have bough the Zetec Black-Top and now we are in the process of match all the other components.

The gearbox [MT75] is perfect it fits with 5 main bolts [not only 4 like some one say] but we have here a left hand drive gearbox.

The start motor from a Sierra fits against the gearbox, but some rework is required to the aluminum sump, nothing special because it is not part of the oil containment, just a reinforcing for the traversal boxes.
We don't need to remove the alu oil pan to do it.

The inlet manifold is very restrictive, the TB has flap with a thick plate at the rear side, and it is very small.

So we have decided to make one our self.
First we have done some 3D design to see how all the components will fit.
We will use all the Zetec components, like the injectors [200 cc @ 3Bar] the fuel rail, the IAC, etc.
The injectors have 4 jets so we are not allow to rotate them, to maintain the good fuel distribution.
Also the injectors should be as close as possible to the inlet valves [spray on the valves] for that reason the injector location is critical and at the top of the inlet manifold flange.

So here are some pictures for information. Some of them are 3D drawings that shows the space and the development.

[Cobra289]

[Cobra289]

[Bonzo]

That is some superb work there

I am sure that it will provide a great deal of direction to others going the Zetec route.

I like the inlet manifold design, Is that an off the shelf conversion or has it been created from scratch ?

[Cobra289]

Originally Posted by Bonzo

That is some superb work there

I am sure that it will provide a great deal of direction to others going the Zetec route.

I like the inlet manifold design, Is that an off the shelf conversion or has it been created from scratch ?

Hi Bozo,
The manifold is designed just from scratch, but following some principles.
Almost something equivalent has been used at the WRC cars, but more important there are experiences with this type to meet the 700 HP in a Opel 2.0 L engine turbo at 2 bar.

I don't like that components of the engine comes outside the body so that is the reason that suck from the rear.

It will fit a RHD car there is enough space for the steering column.

I use the parts of the Zetec, injectors, rail, engine wiring, IAC, but the FPR and fuel inlet line has been flip to meet the lines coming from the rear of the car.

I can make drawings if you are interested, a couple of aluminum sheet and inlet flange plus some flanges for the IAC and the TB.

I will probably use a TB of a Volvo 960 because it has a 65 mm unrestricted inlet butterfly.

See the picture for the space under the filter in relation to the steering column.



Regards,
Cobra289

[Bonzo]

I really do love the whole look of that manifold. That work is a great credit to you

I too have seen that sort of design on high power apps, although to be honest with you. Not got a clue as to the science of it all

Definately be tempted to ditch the bike throttle bodys on my Zetec install in favour of that setup

Any drawings or dimensions would be most welcome.

[flyerncle]

Cobra,your talent is wasted on us mere mortals!
One observation about direction of air inlet being to rear of engine bay will collect hot air.

Amazing work all the same !

[Cobra289]

Originally Posted by flyerncle

Cobra,your talent is wasted on us mere mortals!
One observation about direction of air inlet being to rear of engine bay will collect hot air.

Amazing work all the same !

Thanks!
Nah! the hot air at the engine should be directed via the side panels.
Put the inlet filter behind the radiator will catch a lot of hot air.
Watch the top view or other pictures, than you can see that I put there a vertical gap to get rid of the engine heat.

So what I plan to do is just a box around the filter with some side or top entry of the fresh cold air.

Regards,
Cobra289

PS
I just have started to produce some drawings.