Zetec SE engine

[flat_four]

Has anyone here put a Zetec SE (Sigma) engine in a Westie? I'm thinking of putting a 1600 SE in my new build rather then the standard iron-block Zetec I was planning on.

I know the factory do it now so I guess the bits are available, but does anyone have any direct experience? Just wondering if there are any pitfalls or things I really ought to know before shelling out...

Ta in advance,

John

[westy666]

stand by to be jumped on shortly - quite a few of the guys have the sigma in now so you're in good hands

[Matt Seabrook]

Cracking engine by all accounts. From a run of the mill type thing they seem very reliable.

[BLOGGY S7]

The factory fits this engine now.

see this link

http://www.westfield-sportscars.co.uk/

Go to showroom then module build. Ford zetec SE Sigma.

Only things that I have read about them is sometimes just sorting out the cooling can be tricky but after that they are a superb engine. Got one in my Fiesta and thats great. I mate of mine has a 1.6 Sigma in a Puma with bike throttle bodies that he uses for rallying (road) and sprints etc. He swears by them now.

Make sure you get a phase 2 engine though. The one with the plastic top rocker cover, 2001 onwards.

[slippy]

I'm sure this is the engine Cast Iron is running seems to go well even with his lanky ass in it

[Rory's Dad]

I'm sure this is the engine Cast Iron is running seems to go well even with his lanky ass in it

I think he got it from Shawspeed.  They've got all the kit and the service is supposed to be brilliant      

Rory's Dad

[flat_four]

Thanks Guys, keep 'em coming!  

As I have the standard Zetec starter kit, I have the Zetec engine mounts (not yet fitted), throttle cable, clutch cable and pedal etc. Does anyone know if these can be used or do I have to change them?

In fact, can you still use a cable clutch, or do you have to change to hydraulic?

Do you need to change from a serpentine to a straight FEAD and use the Escort water pump as with the late Zetecs, or relocate the Alternator etc?

John

[cast iron]

Shawspeed   - have all the gear. Bell housing adapter for a type 9 box acepts cable and hydraulic clutches. They do an exhaust as does the factory. I used the Factory manifold and engine mounts. Jon Sharples is the man to contact, he is threatening to come to 3 sisters this Saturday .

Be carefull as to which engine management you use. Omex hasn't done me any great favours

[flat_four]

Thanks for your responses everyone.   Anyone else out there with any experience?

I've just ordered a brochure from Shawspeed so I'll have a good look at that. It certainly looks like good stuff on their website.

Cast Iron: as a matter of interest, what problems did you have with the Omex system? As far as I can make out, the two main systems used on the Sigma seem to be Omex and Weber Alpha and, at the risk of opening a rather large can of worms, I don't really fancy the Weber Alpha...

Anyone know whether the standard Westfield Zetec E mounts will fit, and what mods, if any, need to be made to the drive belts?

Another thing which struck me just looking at my chassis - would I be able to go for a low exit exhaust manifold or will it go straight through the standard straight lower steering column?

Don't suppose anyone's going to the Detling show this weekend with one I could take a peek at?!

Cheers all,

John

[peterrosey]

I'm nearly finished fitting a Zetec SE to my car (Fisher Fury, but similar) and  I'd have to say it's a more expensive exercise than just doing the usual cast iron Zetec. This is mainly due to the cost of the bell-housing (I used the Westfield one), hydraulic clutch (you should be able to run a cable on a Westie).

Also I wanted to run throttle bodies and while the best solution is to use Jenveys (who do an excellent direct-to-head version) they're mega bucks (£1000 plus). As I couldn't fit them on mine due to the bonnet clearance, I used R1 TBs (bought fro £40!) on a custom-made aluminium inlet manifold (£285) from Altiss Engineering - can't recommend them enough, did a beautiful job. I'm also running the original Ford fuel rail/injectors and the Yamaha injectors so fuel supply won't be a problem. The whole lot will be controlled by an Emerald ECU.

As the TBs fouled the OE alternator (which is computer-controlled and has to be converted if you plan to retain it) I had to use a different alternator - went for a 70A Zetec version bought from another WSCC member. This is mounted under the exhaust on a custom-made bracket. I then went to a motor-factors and used a very small ribbed belt to drive it.

Another issue I had was with the water pump. It drives off the back of the drive belt (ie runs other way to crankshaft) so I couldn't just loop a new belt around it. After much head-scratching I opted for a Davies Craig electric water-pump controlled by their new digital device. This has the added benefit of being able to run the engine after the ignition is switched off - useful to avoid hot spots after a track day.

The real beauty of this engine is that it's very light (I can pick it up easily to put it on the engine stand - can't do that with an iron block), has a ladder-chassis bearing support, revs to 8000rpm and has a good design of cylinder head (looks almost gas-flowed from the factory). With cams and TBs it's said to be good for about 200bhp, with more available with more gas-flowing and piston mods.

Finally, it's worth making the point that Caterham evalutate over 80 engines before settling on the Zetec SE as their new powerplant...

[andy jacques]

I have a Factory built with a Zetec Sigma SE engine  now done 500 miles

Feels a very robust and smooth engine, I am pleased i chose this engine as lots of tuning can be done when warranty runs out

Plenty of power even at 135bhp. and has lots orf torque as well at low speeds

very good engine!

[John Loudon - Sponsorship Liaison]

I have a Puma engine in my narrow car (still a Zetec SE but 1.7 instead of 1.6)

It uses a cable clutch which is easy to sort so no need for hydraulic systems. Bell housing are available from A Frame Engineering

I use an Emerald ECU and Jenvey now do direct to head TBs for this engine but mine are DCOE style Jenvey TBs on a custom made manifold which clears the original alternator which is wired up as per any other alternator. Piper do all sorts of cam designs for it and Aldon Automotive in Stourbridge can also offer advice on tuning packages. Pace also sell a dry sump kit for the engine.

With regards to the water pump / alternator belt I just used the tensioner and belt from a 1.25 Zetec SE Fiesta. Fits straight on.

Engine mount wise, the standard mounts have to be binned and some custom brackets made to bolt to the block on the redundant threaded holes left by the power steering and air con pumps brackets.

Its a lovely engine with huge potential  

John

[cast iron]

Peter R. Im suprised at all the re engineering you have come across.  The fisher must be a tight chassis?

To reiterate what i have done

I used the ShawSpeed small alternator with no problems and I used Westfield Engine mounts

For Exhaust manifiold I used the standard Wesfield item which exits in the bottom of the engine bay and misses the steering column

alternatively you could look at Johns article in WW and buy a bonnet exit sytem

Shawspeed produce a cast and machined aliminium bell housing which accepts cable and hydraulic clutches

Injectors though I have found that the standard ford injectors are not man enough for more power, they only flow 160CC/Min. Im definitley going to look to throttle bodies.

[flat_four]

Thanks everyone for your comments.

I've just picked up my engine - a 2001 Zetec SE 1.6 with (allegedly) less than 10k miles on it. A bit of a bargain as it was without EDIS module, alternator, starter and one of the plug leads, but I should be able to get most things easily enough.

I'm sure I'll have plenty more questions before long, but in the meantime, thanks again.  

John