Contour Enthusiasts Group Archives Forums Modifications Zetec Maintenance Doing A Rebuild - I Need Advice

I may be rebuilding a Zetec soon (Type 2) but Im not really sure on what to do. Ive never completely rebuilt an engine before, although I have replaced a cylinder head on another car :rolleyes: Anyway, What should I do parts wise? Turbo is out of the question, student loans take care of those funds. I just want to build a very sporty NA engine that I may drop in my car when my current engine dies (probably very soon the way I drive :p ). My HP goal is 200 or better with the torque curve not far behind, over 180 ft/lbs. I dont need a 300+ HP FWD sedan, maybe RWD, but thats another issue.

So far all that I can think of are new rod bolts (ARP), UDP, aluminum flywheel, Adj cam gears (although I dont see the use unless I upgrade to Kent Cams $600), plugs, wires, ignition coil/distributer, chip, engine management (A'pexi), etc...

I MAY purchase some 12.5:1 JE pistons ($575) to boost the power alil. If I can afford to, Id like to get some cylinder head work done. Definitely exhaust port work and maybe some larger valves or combustion chamber work. I also would like to take as much emissions equipment off the engine as I can.

Any ideas, thoughts, comments, advice???

It sounds like you have the right idea. 200 hp is quite ambitious. I've heard the UDP doesn't actually help that much and can wear out your engine(may not concern you since it probably takes thousands and thousands of miles).

Here are the three things that are (IMHO) the weakest part of the zetec's engine. Two are extrenal one is internal.

Internal:
Head

External:
Intake manifold
Exhaust manifold

If I were to rebuild and drop some coin on performance, it would be head work.

Yes I forgot to mention the exhaust manifold, Focus Sport can take care of that. As for the intake manifold, the only company that makes one is Jenvey .

get TB optimized

under drive pulley doesn't wearout the Zetec the problems with the underdrive pulleys is only on the duratec... with mine I got 2hp and 8TQ with the Esslinger pulley... I think it was well worth the about $70 I paid for it.

If you are considering a full teardown and rebuild with hc pistons,cams etc you will be in the market for some m/c shop work re cylinder rebore/hone,all new followers to go with new cams,maybe even solid lifters to match a hot cam,these need shim adjustment for valve clearences etc.Major engine components(pistons,cams,bearings,rings etc) are not a 'bolt on' to a stock engine.Measurements etc and m/c need to be done for the correct fit.I think you may get in too deep with this unless you have all the equipt to measure and build up a motor ...sorry but just my 2 cents

Don't be sorry Terry, your 2 cents are usually worth countless dollars around here!!

Then what would you suggest that I do in this situation?

What I was planning to do was to have a prolonged engine build up (4 years) since 8 months out of the year I dont live at home (200 miles away) and thats where it would be stored. I just want to have the experience of rebuilding an engine and I figured that since I will be tearing the whole thing apart that I might as well through some aftermarket parts in to it. I will admit that I dont have everything planned out yet (thats the purpose of this topic), but when it come to machine work and the like there are multiple speed shops around. So I do have different routes to take in the case that I experience troubles.

Anyway, since you know what your talking about more than I currently do Terry, What course of action do you suggest I take? Your turbo option has been in the back of my mind lately, mainly because the thought of running 12.5:1 compression and certainly well over 91 octane doesnt settle in my mind.

The first thing to do is to get an engine and tear it down to see what it needs, like machine work, pistons, rods, etc. If all is in good shape, start adding the parts you want based on the direction you're going with the engine. All new parts like all new machine work to snuggle up against.

If I were you, I'd start with a stout short block (block, pistons, rod, and crank). Build it with the correct compression for which way you're going with the build up since the rods and crank will have to be pretty beefy and in good shape for either goal. The head work can always be done at a later date too should the funds fall short of your dream Zetec.