2000cc Ford Base ZETEC Engine

Engines come complete with standard throttle body, loom, injectors and fuel rail, exhaust manifold, plugs and coil pack cables, water pump and sump.

Engines do not come with flywheel or clutch, but these items are available separately.

Call if you need any for more details on the specification.

Please note that the cargo is available, but we have to fully pack the motors for transportation. The packaging has an additional cost of € 90 and shipping will be € 125 for most continental destinations. Call to confirm shipping costs if you are unsure.

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Zetec intake manifold

The intake manifold for the Ford Zetec engine is designed for 45mm Weber DCOE carburettors and will therefore fit most aftermarket fuel injection throttle bodies. It's shorter than most with just 60mm head-to-head, streamlining a more compact installation, especially for those who put the Zetec in an RWD Escort body and for Caterham Sevens owners with flared wings. Unsurprisingly, the intake manifold is beautifully cast and finished in typical Raceline style.

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Zetec Wet Sump Kit

The Raceline Performance Engineered cast alloy sump manifold is designed to allow as much ground clearance as possible when installed in a Caterham Seven or similar vehicle. To achieve this and at the same time ensure adequate oil capacity, the sump should necessarily be wide and shallow, when ideally a sump should be tall and narrow. This is an unavoidable compromise, which could lead to an oil surge, but for the advanced design of the Raceline sump pan with its built-in wide baffle pan, meaning the oil surge is virtually eliminated. However, it does mean that the oil level in the sump is critical.

The sump holds a full five liters, and we recommend that owners recalibrate the oil dipstick to suit the particular installation of your vehicle. Once the engine has been installed in the car, fill the sump with exactly five liters of your chosen lubricant (measuring carefully to ensure accuracy), then lightly write a 'complete' mark on the dipstick. For obvious reasons, you must ensure that the vehicle is located on a flat, level surface. If possible, it is highly desirable that the vehicle be placed in the same location each time the oil level is checked thereafter. You should try to keep the oil level at the maximum mark at all times, checking as often as necessary to ensure this. Raceline has discovered that the Ford Zetec engine is exceptionally oil tight, and rarely, if ever, does it need to be topped up between oil changes in normal service. However, any engine will use some oil if it is subjected to exceptionally harsh use, for example on a racing circuit on track days, especially when oil temperatures are high. Therefore, frequent checks are a must ...

The cast alloy sump pan kit can be ordered to suit different Zetec engine and gearbox applications. The main sump castings are machined for inlet or exhaust side starter mounting. Sump kit internal components are also available to accommodate different initial 'Silver Top' and later Focus 'Black Top' engine designs. Complete assembly instructions are supplied with each kit.

As long as oil levels and temperatures are kept to a satisfactory level, the Raceline Performance Engineered designed wet sump has proven to be completely reliable, even in the use of hard circuits.

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Injection bodies

Raceline has worked with Jenvey Dynamics and Omex on throttle body designs and applications for many years. With years of very positive experience we have had, we are convinced that your throttle body designs are the lightest, most reliable and cost effective on the market. Raceline stores a wide range of throttle bodies to suit standard manifold applications. Available in 42mm, 45mm or 48mm sizes, and finished in a crinkled powder coated black finish, the throttle kits are machined with O-ring grooves to seal directly to the manifold and include vacuum bleed fit. Fuel rails are available to operate the injectors in the throttle bodies with pressure connections or -6. A range of ram tubes, air filters and throttle links is available for 45mm and 48mm throttles. If you don't see a suitable component listed, please contact us.

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Pistons and connecting rods

Raceline has a range of high-forge pistons for the Zetec engine designed to accommodate different levels of performance. To complement the pistons, Raceline also has a range of lightweight steel connecting rods, all equipped with high-strength ARP connecting rod bolts. Standard and tri-metal connecting rod bearings are also available.

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Cylinder head upgrades

Raceline cylinder heads have a good reputation for detail, excellent finish and, of course, performance. Obtaining substantial improvements from what is already a reasonably efficient modern design multi-valve cylinder head is not an easy task, it is only possible because the reviews we do are carried out with the help of a flow bench, an essential ingredient in any modified cylinder head .

Our most popular upgrade, using the RL200 camshaft kit, brings a standard 160 bhp 2000cc Zetec engine in carburetion to 190bhp (200bhp in injection). The work includes cleaning and balancing the inlet and exhaust ports, a head skimmer to increase compression to 11: 1, and profiling work on the valves to improve flow. The inlet manifold also fits the cylinder head.

The next level takes an injected Zetec up to 220 bhp and includes the same port work, but with the additional work required to fit a larger 32mm cam follower. This allows the Zetec to run a higher elevation camshaft, resulting in higher performance.

Beyond 220 hp, larger valves are used to complement the higher performance cam profiles, where high revolutions are available on performance rods and forged pistons.

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Steering wheel and clutch

Zetec-R lightweight flywheels are machined from EN8 steel and are designed to have a inertia stock or a pre-engaged Ford sprocket. The steel flywheel repositions the ring gear in the same position as the Ford Crossflow flywheel, making it possible for those performing the upgrade to retain their existing starters. The flywheels come machined with 36-1 timing holes to fire the trigger on the crank according to a standard flywheel. Flywheels are available to take 8 1/2 "and 7 1/2" clutches, and a 7 1/4 "stroke option is available upon request.

Flywheel weight (less ring gear) = 5.5 kg

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Dry sump kits

Raceline can supply 2- and 3-stage dry sump kits to suit a variety of Zetec installations. All kits have an external pump driven by an additional crankshaft pulley. The Stage 2 pump has two sweep rotors and uses the standard OE pressure pump. The stage 3 pump has the same flush rotors but with an additional pressure stage.

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