Table of Contents: Phase One

Junk Yard Zetec Project Background

Powerplant Acquisition

Disassembly

Modification of the Stock Block

Crankshaft and Flywheel

Cylinder Head: Disassembled and Reassembled

Pistons, Block and Cylinder Head Reunion

Stock Oil Pump Cover Modification

Camshaft Reinstallation and Alignment

Water Pump Housing Installation

Timing Belt and Pulleys

Front and Cam Covers

Dry Sump Pan

Water Pump Installation

Water Outlet and Thermostat

Oil Pump Installation

Oil Filter Installation

Clearance for the Engine Stand

Intake Manifold Assembly and the O-Ring Requirement

Air Scoop Assembly

Exhaust Header

Motor Mounts

Alternator Kit Installation

Transition from the Mechanical to the Electrical

Performance Electronics Factory Wiring Diagrams

Relay Wiring Diagrams

Preparing for the Wiring Process

Coil Wiring

Injector Wiring

Upper Sensor Branch Wiring Diagram

Fuel Pressure Sensor Placement and Wiring

Throttle Position Sensor Placement and Wiring

Air Temperature Sensor Placement and Wiring

Cam Sensor Placement and Wiring

MAP Sensor Placement and Wiring

Lower Sensor Branch Wiring Diagram

Crank Position Sensor Placement and Wiring

Oil Temperature Sensor Placement and Wiring

Oil Pressure Sensor Placement and Wiring

Water Temperature Sensor Placement and Wiring

Project Completion

Parts, Tools and Services (With Totals)

Consultants, Suppliers and Craftspeople

 

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