Before you start
The guides on the following pages will supply you with the basic information to install the engine and, if applicable, gearbox only. Remember that installing a Zetec will be a performance enhancement, and so the suspension and brakes on your classic Ford should also be uprated accordingly!
MK1 AND MK2 FIESTA
Using OE parts can make this swap look factory — if that’s the way you want to go...
Engine choice Of the several types of Zetec, it’s the 2-litre Silver Top that has the most amount of adaptable parts — the oil pump/filter system for starters. And don’t dismiss the 1800 — it’s components are very adaption-friendly, as we’ll see...
Engine mounts Dimensionally, the Zetec’s almost identical to the CVH, which formed the basis of the Mk2, which of course was formed from the base of the Mk1. The top engine mount needs refabricating since one of the bolt holes needs adapting, but this is already very well documented.
Sump In Zetec sump-speak, the Mk5 Escort type is a front-bowl and of aluminium construction. This is important because it allows easy exhaust routing; down the centre of the car, and off-the-shelf exhaust systems are already available to suit this configuration. Don’t forget you need the oil pick-up pipe, too!
Offside chassis rail The Zetec is wider than the Mk1’s engine bay so this area also needs some adaption to clear the crank pulley. The most common route is to chop out a section to form a clearance pocket using chassis-thick sheet steel.
For the offside, use the single-piece driveshaft from a Mk2 Fiesta XR2, while the nearside shaft from a Mk1 XR2 works best on the other side. On top of this, the engine cradle and bearer from a 1300 or XR2 (which also has spacer blocks to lower the engine) can be swapped in
