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1 If You've bought a Mondeo Zetec engine, then you'll need to remove the sump and replace it with a front-wheel-drive Escort item to clear the original Elan cross member. The oil pick-up pipe has to be changed too. Ten bolts hold the sump on, while a Torx 30 bolt holds on the pipe. |
2
Make sure you Loctite the pick-up pipe fixing, so it can't drop off inside the sump. Use a gasket sealant on the corners of the sump, where it meets the joins between the cylinder block and the casings above. Be sure to do up the sump bolts evenly so it doesn't warp. |
3 You'll also need to make sure that your engine has a flywheel sensor and holder. If not, buy them from Ford or from a breakers yard. Bolt the holder into place like this on the back side of the engine. The sensor bolts in from the other side later (so don't damage it). |
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| 4
Fords fwd Zetec engines don't have a spigot bearing but you'll need one. Spyder supplies one that taps into the end of the crankshaft. First smear some high point grease inside the end of the crankshaft. |
5
Use an Escort flywheel as it's the lightest stock Ford item. Lighter flywheels are available from Raceline and Dunnel but they're unnecessary for a road car. Flywheels will only fit one way due to the spacing of the mounting holes. |
6
Before fitting the clutch, make sure the driven surface of the flywheel is free of corrosion and dead clean. Wipe it down with a degreaser. Use an Escort clutch and alignment tool to get it central as you bolt it on. |
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| 7
Unbolt the front pulley, the cam cover and the upper and lower front covers. Turn the engine until these slots in the cams (at the back end of the engine) line up and the notch in the crankshaft pulley lines up with a lug on the sump. Use a bar to keep cams in place. |
8
You need to make sure you've got the correct water pump on your engine. An Escort pump, the one you need, has a straight outlet pipe, a Mondeo's is angled. Swap the pump and idlers if necessary. You'll need a torx 50 bit to undo the pump fixing bolts. |
9
Fit a new cambelt, tension it using a 6mm Allen key and a torx 50 bit on the tensioner wheel, turn the engine over twice and check the tension. You should be able to twist the belt 90 degrees on it's longest run. Check that the timing is correct then refit the covers. |
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PRACTICAL CLASSICS MAY 2003