Zetec swap 88 xr4ti

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foundnemo25
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Zetec swap 88 xr4ti

Post by foundnemo25 » Sun Feb 21, 2016 1:16 pm

Well I'm new here. I had done quite a bit of research on the zetec swap. I have seen one attempt it over the years aND many went other routes. Well I had a little time this weekend, and wanted to show some progress .

This is how it sits right now as I am posting this on the forum.Image
Image

Drivers side engine mount Image

Passenger side engine mountImage
I have been taking a lot of pictures lol.I have wired in megasquirt 2 with the relay board and it cranks at turn key. I have some turbo manifold pieces to order.
The engine came out of my zx2 compound turbo setup. Fully built from svt focus head to the bottom end. I am deciding if I want to put the compound turbo setup on it while it is in the merkur. Haven't made up my mind yet.
Its not what you build, its how you build it.
1988 Merkur XR4TI 393W Turbo Setup
1986 Merkur XR4TI Stock wife's little beater

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DPDISXR4Ti
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Re: Zetec swap 88 xr4ti

Post by DPDISXR4Ti » Sun Feb 21, 2016 2:54 pm

Look forward to seeing the progress on this. I also recall that years ago (at least 10), someone started on a Zetec swap, but never got very far with it. IIRC, the bell bolt pattern is mostly the same as the Lima, yes?
Brad

foundnemo25
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Re: Zetec swap 88 xr4ti

Post by foundnemo25 » Sun Feb 21, 2016 3:42 pm

The bolt pattern is roughly the same , besides the top two bolts. On the 2.3 engine it you look at the mating side of the engine,you will see 4 upper bolts, 2 lower and 2 higher. The lower two are the same as the zetec. I just drilled and tapped the block to accept the upper bellhousing bolts. Now it's held by 5 bolts.
Its not what you build, its how you build it.
1988 Merkur XR4TI 393W Turbo Setup
1986 Merkur XR4TI Stock wife's little beater

hEaT
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Re: Zetec swap 88 xr4ti

Post by hEaT » Mon Feb 22, 2016 9:36 am

Cool. Is that an SVT Focus head with a VCT delete?


The motor mounts...are going to to reinforce those a bit?
Joe
1985 Nimbus Grey XR
2017 Ford Focus RS

foundnemo25
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Re: Zetec swap 88 xr4ti

Post by foundnemo25 » Mon Feb 22, 2016 11:49 am

Yes that is the svt cylinder head with the delete. The mounts are tack welded in the picture. I have welded them completely last night and making guset to connect them together
Its not what you build, its how you build it.
1988 Merkur XR4TI 393W Turbo Setup
1986 Merkur XR4TI Stock wife's little beater

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mopman93
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Re: Zetec swap 88 xr4ti

Post by mopman93 » Tue Feb 23, 2016 11:25 pm

cool,

how much clearance from back of head to firewall? what oil pan and issues clearing the crossmember? Does the zebec use a water rail from the back of the head to the top of the radiator?

These are all issues I had to when putting in my duratec, would be interested in how you are going about it.

foundnemo25
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Re: Zetec swap 88 xr4ti

Post by foundnemo25 » Wed Feb 24, 2016 1:58 pm

There is about 3 and a half inches between the engine and the firewall, yes the zetec needs a water rail fo the thermostat due to the original placement of the thermostat housing. The oil pan is a contour pan 95-97, and modify the crossmember to clear.
Its not what you build, its how you build it.
1988 Merkur XR4TI 393W Turbo Setup
1986 Merkur XR4TI Stock wife's little beater

foundnemo25
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Re: Zetec swap 88 xr4ti

Post by foundnemo25 » Wed Feb 24, 2016 6:14 pm

Deciding on single turbo or compound turbo setup

Image
Image
Mock up for compound setup to give me a rough idea of position. Turbos will be more forward to give clearance to the brake master cylinder and room for downpipe.

Image
Its not what you build, its how you build it.
1988 Merkur XR4TI 393W Turbo Setup
1986 Merkur XR4TI Stock wife's little beater

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merkurdriver
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Re: Zetec swap 88 xr4ti

Post by merkurdriver » Wed Feb 24, 2016 6:33 pm

:cheers Cool project!

GPz11
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Re: Zetec swap 88 xr4ti

Post by GPz11 » Sat Feb 27, 2016 8:26 am

I would put in some type of heat shielding near the master cylinder. On my old set up, I melted the plastic expansion tank with a center mount header and non water cooled turbo.

Otherwise cool build!

foundnemo25
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Re: Zetec swap 88 xr4ti

Post by foundnemo25 » Tue Apr 05, 2016 8:07 pm

Update of the build,
For clearance with the power steering rack, it was either lower the rack position or modify the oil pan. I decided to make an oil pan seeing that I didn't have the ability to weld aluminum .
Image
The room between the cylinder head and the fire wall was roughly 3 inches, not enough to use the factory thermostat housing , and the option of buying one over seas, was not cost efficient. So I decided to make one.ImageAs of right now, this is how she sitsImage

There is only a few things left to do until she is driving. After the engine side is done, I am working on the body side of it
Its not what you build, its how you build it.
1988 Merkur XR4TI 393W Turbo Setup
1986 Merkur XR4TI Stock wife's little beater

espacef1fan
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Re: Zetec swap 88 xr4ti

Post by espacef1fan » Wed Apr 06, 2016 1:10 am

I was going to attempt this swap until I stumbled across a nice adapter plate for a Duratec/T5

I still think of this swap alot though! Cool build! Please keep us updated with LOTS of pictures. and notes!
Adam Escott
Fort Campbell,KY
Chinook Mechanic
89 XR with Outcast Body in Red
Duratec coming soon(unless you havea a better idea...)

foundnemo25
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Re: Zetec swap 88 xr4ti

Post by foundnemo25 » Wed Apr 06, 2016 1:07 pm

espacef1fan wrote:I was going to attempt this swap until I stumbled across a nice adapter plate for a Duratec/T5

I still think of this swap alot though! Cool build! Please keep us updated with LOTS of pictures. and notes!
I will post notes or answer questions about the swap. It's not too difficult at all. I do have a large amount of pictures , I just don't want to flood this thread with pics
Its not what you build, its how you build it.
1988 Merkur XR4TI 393W Turbo Setup
1986 Merkur XR4TI Stock wife's little beater

espacef1fan
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Re: Zetec swap 88 xr4ti

Post by espacef1fan » Wed Apr 06, 2016 5:59 pm

foundnemo25 wrote:
espacef1fan wrote:I was going to attempt this swap until I stumbled across a nice adapter plate for a Duratec/T5

I still think of this swap alot though! Cool build! Please keep us updated with LOTS of pictures. and notes!
I will post notes or answer questions about the swap. It's not too difficult at all. I do have a large amount of pictures , I just don't want to flood this thread with pics
Its actually helpful to document with pictures and text of all the custom work youve done. It helps people in the future do the swap, especially if you sell the car and move on and arent around to answer questions.
Adam Escott
Fort Campbell,KY
Chinook Mechanic
89 XR with Outcast Body in Red
Duratec coming soon(unless you havea a better idea...)

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