Build Diary 5

Build Diary Page 5

• Engine and gearbox.

The engine and gearbox are fitted as a complete unit. The Zetec engine is intended for a front wheel drive car, so the first job was to fit a Raceline water rail which moves the position of the thermostat housing to a more convenient position.

Next the gearbox can be fitted to the engine. A new clutch release bearing was fitted to the gearbox input shaft. It took a few attempts before the gearbox splines lined up with the engine's. But eventually it went together with a sudden forward movement. Quick get the bolts in!

The engine is a 1.8 Zetec from the Escort. The gearbox is a type 9 Sierra. Hence they don't fit together perfectly, the bell housing doesn't match up exactly. There is a gap that needs to be filled in, so my Dad fabricated a stainless steel cover to fill in the hole, nice one!

Now comes the "fun" bit, fitting the engine. A proper engine hoist is a must for this job!

It's a tight fit especially with the gearbox attached. The whole unit has to be tilted at quite a steep angle. Its a case of lowering it slightly then moving the whole thing forward a bit then lowering again. Slowly but surely it landed home on its gearbox and two engine mounts. Phew!!