- German Escort RS Cosworth '95 sales brochure (6 pages).
First, a Ford Escort CL '92 was acquired for parts after it had gotten itself stuck in a tree post. Later, a Ford Escort Special '94 came for daily driving.
Brief history:
The Zetec was introduced in 1.6l and 1.8l Escorts and 1.8l Fiestas in 1992. The Mondeo got a 2l version, which was released in 1993. On older Zetecs, the valve cover only reads DOHC. Yamaha was involved in the design of the Zetec cylinder head, and the block is an improved CVH block. The next step was the 'Black top' Zetec, which has more material between the cylinders and a sharpened timing belt. The latest and most powerful Zetec was the Focus ST170 version.
MK5 model has three variations.
First was with old rear lights and front grill.
MK5a bring new rear lights and center console was longer and new grill at front.
MK5b brought shorter center consoler and now with gas door
not just cap anymore
Seat attachment points was changed too slightly. I noticed this with seats.
Behind the rear fender on the fuel cap side is the Canister Purge Valve(?) if anyone is looking for it.
In my own experience, the first fault was a valve leak, which caused high HC levels. Symptoms included stalling when cold.
Korvaavan kannen päätin repiä varaosa autostani ja yllätys yllätys siinäkään kaikki venttiilit eivät olleet tiiviitä, joten vaihtoehdoksi jäi kannen kunnostus. Kannen jätin purkamisen jälkeen paikallisellePJK-Kansityö Ky:lle. Samalla tuli vaihdettua kaikki mahdolliset tiivisteet ja hihnat uusiin.
Of course, some minor experimentation was done too, and I swapped 1.8l camshafts, the throttle body, the MAF (housing), and tore apart the head.
Common problems include the fuse box solder joints and wear on the stalk switch contact surfaces, which can cause all sorts of electrical issues.
Henkiläkohtaisia esimerkkejä:
Stalk switch:
Horn sounds unexpectedly
Headlights flicker on high beam or all lights go out completely
From the rear fog light button you could switch the right headlight on and off (momentary interference)
...
Fuse box:
The fuel pump relay clicks more than once when turning the key. (This was a warning and later it died on the road)
There are different types of fuse boxes. The 92 CL model had a 28-fuse size and the 94 (Special/CL) had a 34-fuse size. They are not interchangeable since they have different wiring. A clear difference is that the newer one has only one separate positive connector and the old one has three.
Below are the fuses for the 28-fuse model (93AG-14A073-BA). (F29 is found among the relays)
F1 25A Rear Window Heater? F18 15A High Beam (Left) F2 30A ABS F19 3A ABS F3 10A Motor Control (LAMBDA/KAT) F20 15A Warning Lights F4 15A Right High Beam F21 15A Interior Lighting + Radio F5 20A Fuel Pump F22 30A Electric Windows F6 10A Parking Light (Left) F23 30A SWRA F7 10A Parking Light (Right) F24 10A Low Beam (Right) F8 10A Fog Light (Rear) F25 3A KAM Memory F9 30A Air Conditioning F26 15A Seat Heaters F10 10A Low Beam (Left) F27 15A Brake Lights, Motor Control? F11 15A Fog Lights F28 15A Motor Control (ECU?) F12 10A Indicator + Reverse Light F29 25A Central? (Läytyy releitten seasta) F13 20A Wipers F14 20A Electric Fan F15 30A ABS F16 3A WSSH F17 -- Airbag
34-fuse model (96AG-14A073-EB).
F1 10A Rear Fog lamps F18 30A Electric Windows F2 -- F19 -- F3 10A Parking Light (Right) F20 25A Cooling Fan F4 -- F21 3A ABS F5 15A High Beam (Left) F22 30A Air Conditioning F6 15A High Beam (Right) F23 15A Seat Heaters F7 3A KAM Memory F24 20A Wipers F8 10A Parking Light (Left) F25 30A ABS F9 30A ABS F26 10A Indicator + Reverse Light F10 30A SWRA F27 25A Rear Window Heater? F11 10A Instrument Lighting F28 15A Warning Lights F12 7.5A Airbag F29 15A Interior Ligthing F13 20A Motor Control (ECU?) F30 20A Central Locking System F14 10A Motor Control (LAMBDA/KAT) F31 15A Fog Lights F15 10A Low Beam (Left) F32 15A Motor Control (ECU?) F16 20A Ignition F33 20A Fuel Pump F17 10A Low Beam (Right) F34 34A Brake Lights
Specs of stock injectors:
RS2000 - Bosch 0280155504 - 250cc/min (3bar) - 14Ω Zetec 2.0 - Ford 948F-B2B (beige) - 225cc/min (3bar) - 14Ω Zetec 1.8 130PS - Bosch 0280155503 - 190cc/min (3bar) - 14Ω Zetec 1.8 1x5PS - Bosch 0280155819 - 185cc/min (3bar) - 16.3Ω? Zetec 1.6 90PS - Ford 948F-AB/A2A (black) / 567 31 2471 - 150cc/min (3bar) - 14Ω CVH 1.6 - Lucas 5207007 - 147cc/min (3bar) - 14.4Ω According to Ford, i.e. read from the ECU: RS Cosworth 2.0 T25 - - 337.2cc/min (*COSY, CARD) Zetec 2.0 136PS - - 229.8cc/min (*DEEP, DESK) Zetec 1.8 130PS - - 208.3cc/min (*2FBC, 2FDC) Zetec 1.8 115PS - - 266.0cc/min (*SLUG) ? Zetec 1.8 115PS - - 229.8cc/min (*SEAL) Zetec 1.8 105PS - - 208.3cc/min (*2FCD) Zetec 1.6 90PS - - 141.9cc/min (*ENVY) Zetec 1.6 88PS - - 139.1cc/min (*HIDE)
The plan was to swap the engine for a larger one and the gearbox for a stronger MTX-75 from the current BC5 transmission. I noticed a detail that helps with identification... The visible part of the MTX-75 clearly has more lines that create a grid-like pattern.
The gearbox can be found in the following (but always make sure when buying a donor):
Escort - TDi, XR3i, RS2000
Focus - diesels and 2.0 Zetec
Mondeo - (also 1.8?) 2.0 Zetec
I'll clarify later exactly which ones work since there are slightly different versions:The MTX comes with hydraulic and mechanical clutches, cable and lever gear shifts, starters in different positions, and engine ear mounts are in different locations.Source*
The IB5 box is also distinguished from others by its own pattern, which was apparently introduced in MK6 Escorts replacing the BC5 box.
Exhaust manifold! A topic often discussed online in many places. Here shortened.. The original is cast and you shouldn't cut the flange from it since the material differences work against each other. Stainless is otherwise good but more prone to breaking. Aluminum, a softer material compared to others, so it's left out. Sheet metal, i.e. sheet metal exhaust manifold. A titanium one is an option if you have the money...
Turbocharging!
Short list -proturbo.fi
Ennen 1.7.1987 käyttäänotetut ajoneuvot:
For inspection, a normal exhaust gas emission test and modification inspection procedures are sufficient.
The E-regulation 15/03 applies to vehicles regarding emissions.
Ennen vuotta 1992 käyttäänotetut ajoneuvot:
Päästäjen osalta autoja koskee sääntä E 15/04. Helpoin tapa on asentaa katalysaattori mikäli auto ei ole merkitty vähäpäästäiseksi. Ahtimen tai ahtoilman jäähdyttimen asennuksen tai ahtimella varustetun moottorin muutoksen, esim. ns lastuvirityksen, jälkeen on moottorin teho selvitettävä tehomittauksella.
Vehicles from 1992 and newer:
Installing a turbo on a naturally aspirated engine is practically impossible. Installation always requires an emission test (prices from 924.8€ incl. VAT 0%) unless an original turbo engine with accessories available in the model series is installed, for which a certificate of exceeding E 15/04 emission standards must be obtained from the manufacturer's representative.
Escort / Zetec / general information:
Windshield - Ford Escort-(Original source)
Ford Wiki - Escort (English)
Ford Escort.ru (English)
Ford ETISVehicle information by part number
Zetec Project Fiesta - 76s.net
Zetec Article - RE85
Zetec Article - Turbo FAQ #1 (English)
Zetec Article - Turbo FAQ #2 (English)
Putting a Zetec in an Escort mk1/2 cockpit - Magazine Article (English)
Zetec Intake Comparison (English) - 1.6/1.8/2.0 & 130HP
Information on FWD gearboxes (English) - BC/MTX-75/IB5
Engine code location
Engine code information
Engine code information #2 (English)
Engine information (English)
Engine information (English) #2
Koneviesti.fi Article - Starter Repair
Koneviesti.fi Article - Alternator Restoration
Escort RS2000 - AWD, manuals...
Information on EDIS ignition
Magazine articles (English) - Technical & Tuning Articles by Stewart Sanderson
Wideband comparator comparison (English)
Raceline (English)
Burton Power (English)
MDR engines (English)
Troubleshooting table for older cars
Common car faults
Powertrain part 1 - AKE
Powertrain part 2 - AKE
Lowering memojaCHANGING VEHICLE SUSPENSION HEIGHT WITH SPRING CHANGES - Trafi
Percentage calculator
Change percentage tablesjaFinlex attachment
