Forums Forums Enthusiast Forums A - Z Autowirral 2.0 Zetec Turbo build

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