Ford Zetec Tuning - RACELINE

ZETEC-R ENGINE COMPONENTSQtyScrews – thermostat securingPressure capFan switch (thermostat housing)Temperature sender (dashboard)Temperature sender (ECU)Elbow 90º (water rail – heater only)Taper plug (water rail – no heater)Twin coil pack including mounting bracketRACELINE coil pack lightweight mounting bracketRACELINE spark plug lead kitSpark plug (NGK)Flywheel ignition pick up, housing and bolt111111111141Price /each 0.75 5.10 11.00 13.28 10.88 2.95 0.75 44.70 23.00 22.00 5.95 21.75RACELINE inlet manifold – carburettor or injectionScrew – inlet manifold securingGasket – inlet manifold (heat sink gasket)Weber carburettors – 40 and 45DCOEWeber trumpet (ram pipe) – 40DCOEWeber trumpet (ram pipe) – 45DCOEK & N air filter – Caterham styleWeber underslung throttle linkage – single cableWeber DCOE to inlet manifold mounting studsWeber misab plates – carburettor to manifoldWeber nyloc nuts – carburettor to manifold securingWeber rubber cupsWeber cup washersWeber chokeWeber main jetWeber air corrector jetWeber idle jetWeber pump jetWeber spill valveWeber emulsion tubeWeber throttle potentiometer kitECU module – (Ignition only)Wiring loom to suit above ECUAdjustable fuel pressure valve1101211118288164444424111195.00 0.45 15.92 235.00 16.00 16.00 37.50 55.00 1.00 6.20 0.12 0.70 0.40 14.30 3.20 1.85 2.50 3.85 3.35 11.25 36.60 350.00 95.00 28.70Oil filterOil filter threaded bushOil pump 1800cc (external oil pressure release)Oil pump 2000ccOil pump bolts – shortOil pump bolts – longFront cover gasketFront cover oil sealSump gasketSump bolt (set)1111421111 2.95 2.16 94.78 94.78 0.30 0.35 0.67 2.39 10.32 4.00Gasket set – completeGasket set – head only – except head gasketGasket set – bottom end only – except head gasket111 67.50 32.00 18.75TEL 44 (0)1483 – 811978 or 810812FAX 44 (0)1483 – 810801

ZETEC-R ENGINE COMPONENTSQtyRACELINE wet sump kit – cast aluminium high clearance sump with race specificationbaffling, cooling fins, alternator mounting bosses, integral oil pick up with removable fingerfilter. Holds the 5 litre oil capacity required for the Zetec. The ultimate wet sump assembly1Price /each 359.00RACELINE dry sump kit – three-stage pump (twin scavenge/single pressure) includesRaceline cast dry sump pan, three-stage pump, mounting plate, special Formula Ford typeoil filter housing and all brackets and fittings. Tailor made for the Caterham / Westfield1 750.00RACELINE dry sump kit – two-stage pump (twin scavenge) includes Raceline cast drysump pan, two-stage pump (uses OE engine oil pump for pressure)1 495.00Oil temperature senderOil cooler kitDry sump tank – easy clean typeDry sump braided oil line kit1111 35.00 125.00 145.00 125.00Starter motor – pre-engaged Crossflow typeGeared starter motor – 1.5kw (high power suitable for injection engines)11 82.50 275.00Alternator (available for left or right-hand mounting)RACELINE alternator mounting kit – mounts on the exhaust side on the sump pan. Suitablefor Caterham Seven applicationsRACELINE alternator mounting kit – mounts on the induction side below the carbs/injection.Available to suit Mondeo or Focus Zetec engines)Alternator pulley (standard)RACELINE lightweight alternator pulleyAlternator belt – various lengths available11 127.22 135.001 135.00111 11.00 32.00 11.50Engine mounting kit – inc 2 x powder coated engine mounts, bolts and washersStainless steel exhaust system – 4-into-1 tuned length system designed on the dyno formaximum torque and power – side exit system includes clamp and rear muffler mountStainless steel exhaust flangeStainless steel exhaust primary setStainless steel collectorStainless steel silencer11 95.00 625.001111 65.00 295.50 135.00 255.00Water hose kit inc three silicone purpose manufactured hoses (blue) – alloy black anodisedwater pipe inc heater take off – all clamps and fittingsWater hose kit inc one black silicone purpose made hose and two standard hoses - alloyblack anodised water pipe inc heater take off – all clamps and fittingEngine breather kit inc breather bottle, all hoses, elbows and fittings1 150.001 115.001 29.50Caterham injection fuel tank kit inc tank, fuel filter, hoses, filler neck, cap, banjos, washersand pump1 375.00Aluminium bell housing – with integral 30mm spacerAluminium bell housing – aluminium version of the standard bell housing11 235.00 195.00TEL 44 (0)1483 – 811978 or 810812FAX 44 (0)1483 – 810801

GEARBOX & DIFFERENTIALQtyPrice /eachSierra Clubman 5-speed s/c c/r gearbox (with exchange box or 125.00 surcharge)Sierra Clubman gearkitSierra Clubman gearbox – helical cut gearsSierra Clubman gearkit – helical cut gearsSierra heavy duty gearbox (with exchange box or 125.00 surcharge)Sierra heavy duty gearkitSierra dog engagement gearbox (with exchange box or 125.00 surcharge)Sierra gearbox alloy main caseSteel baulk rings Sierra/Rocket/BulletHeavy duty operating block1111111111 895.00 531.89 985.00 775.00 1095.00 760.00 2150.00 270.00 60.00 60.00Rocket Clubman 4-speed s/c c/r gearbox (with exchange box or 75.00 surcharge)Rocket Clubman gearkitRocket heavy duty gearbox (with exchange box or 75.00 surcharge)Rocket heavy duty gearkitRocket heavy duty dog engagement gearbox (with exchange box or 75.00 surcharge)Rocket Range Change gearbox (with exchange box or 75.00 surcharge)Rocket Range Change dog engagement gearbox ( w/exchange box or 75.00 surcharge)Rocket alloy main case11111111 650.00 400.00 965.00 670.00 1250.00 1700.00 1950.00 270.00Bullet 4-speed s/c c/r gearbox (with exchange box or 100.00 surcharge)Bullet gearkitBullet dog engagement gearbox (with exchange box or 75.00 surcharge)111 960.00 600.00POAEscort Sport/Mexico 4-speed s/c c/r gearbox (with exchange box or 75.00 surcharge)Escort Sport/Mexico gearkit11 700.00 500.00Sierra 7inch differential 4.1:1 crown wheel and pinionSierra 7inch differential 4.44:1 crown wheel and pinionSierra 7inch differential 4.7:1 crown wheel and pinionSierra 7inch differential 2.9:1 & 3.14:1 crown wheel and pinionSierra 7inch differential 3.62:1 & 3.92:1 crown wheel and pinionSierra 7inch limited slip differential unit – QuaifeSierra 7inch limited slip differential unit – ZF1111111 485.00 485.00 485.00POAPOA 475.00 650.00Differential Rebuild ServicesVapour blast differential case and diff carrriersPlating diff flange, tabs, bolts etcCrown wheel boltPinion head bearingPinion tail bearingDifferential bearingPinion oil sealDifferential oil sealDifferential ‘O’ ringCompressible spacerPinion nutFlange nutBreather tube11101121221111 75.00 15.00 0.36 25.00 22.00 16.00 8.15 5.24 0.90 2.67 2.95 1.75 0.99Rebuild labour – differential complete1 125.00TEL 44 (0)1483 – 811978 or 810812FAX 44 (0)1483 – 810801

Introducing.Raceline Cars Limited was founded in 1994 by ChrisSmith and former Formula One engineer PeterMcEwen, primarily to develop the recently-introduced Ford Zetec engine for club motorsport and fastroad use. Although the company has diversifiedsince, a range of specialist components and tuningpackages for the Zetec remains the company's mainstock in trade.For various reasons - possibly to do with the lack ofany real motorsport pedigree - the Zetec engineseems to have been overlooked by many enthusiasts. Raceline Cars Limited was among the first companies to spot the potential of the engine, and weremain convinced it has much to offer. In developingour range of tuning packages and special components for the engine, we have found it to be extremely robust, durable, and efficient. It also respondsextremely well to even modest tuning. In commonwith most modern engines, it is remarkably oil tight,a particular attraction to those still using the ageingFord Crossflow. For all of those reasons, then, theFord Zetec is the ideal basis for a modern high performance engine. The fact that it is manufactured inlarge numbers and is therefore available at modestcost, either new or second-hand, is another significant point in its favour.Certainly Raceline's early faith has been fully vindicated as the engine is increasingly seen as a viablealternative to rival powerplants from Rover, Vauxhalland others. During 1998, Ford introduced the WorldRally Championship version of the new Ford Focus(and signed Colin McRae to drive it) powered by aspecially-developed turbocharged version of theZetec, so giving the engine still more kudos andcredibility .As stated, Raceline has developed a range of tuningpackages for the Zetec engine. For obvious reasonsthese are based around the 2-litre version of the Zetec,but if for any reason you should wish to use a1.6-litre or1.8-litre version for a particular application, we arealways happy to discuss your requirements on an individual basis. An otherwise standard 2-litre engine, running on twin sidedraught Weber 40DCOE carburettors(where permitted) will produce an easy 160bhp. TheRaceline 160 Sport engine gives you just that, either inthe form of a brand new factory-built Ford unit fitted withthe relevant Raceline components, or as a kit of parts toenable you to source your own 2-litre engine and fit thespecial Raceline components. This is a perfect upgradefor any ageing Crossflow-powered Caterham Seven,and naturally Raceline offers a full fitting kit for installinga Zetec in the Seven, including an F1-style exhaust system that could truly be described as a work of art. Notcheap, but if you take pride in your car, as most enthusiasts do, it's the perfect finishing touch.Appearances are important, and from the outset,Raceline's intention has always been to mimic as nearly as possible the look of the classic Ford performanceengines, notably the BDA. That is why we designed ourown cast alloy water rail for the Zetec, which hugs theleft-hand side of the cam cover and places the thermostat in the BDA position, near the front of the engine.This greatly simplifies and tidies up the plumbing of thecooling system when the engine is installed in-line, in aCaterham Seven or similar, enhancing the under-bonnet presentation, and further reinforces the likeness tothe classic BDA, still so revered by many Ford enthusiasts. Indeed, although the Zetec is often touted as areplacement for the venerable Crossflow, in size,weight, and especially power output, it should more correctly perhaps be considered as a replacement for theBDA. Please bear this in mind when comparing prices.

The Raceline cast alloy wet sump pan and fitting kit isanother product of which we are especially proud. Sure,you can save some money by hacking a standard Fordcast sump pan about and rewelding it to suit. But leavingaside the rather makeshift appearance of a cut-and-shutcast sump pan, bear in mind the standard Zetec enginewas designed by Ford for transverse installation in asaloon car with inherently modest cornering capabilities.Obviously the baffling can be modified to suit the in-lineinstallation, and to counteract the greater 'g' forces generated by a fast-cornering Caterham Seven or similarvehicle, but can this ever be as satisfactory as a true purpose-designed unit? So, although on the face of it theRaceline wet sump pan may seem an extravagance,even the most cursory inspection should convince youthat it's worth it. It is, as they say, a proper job.At the other end of the scale to the budget 160 Sportunit, a full Raceline-built engine with some cylinderhead modifications and special cams will produce atractable and reliable 225bhp on fuel injection.Raceline offers a range of options in between. Forthose with a hankering for even more power, torque,and speed, Raceline offers a range of special parts,like steel billet crankshafts, steel H-beam connectingrods and forged pistons, not forgetting our superb drysump kit, allowing higher rpm and hence even greaterpower outputs. Again, please feel free to contact us todiscuss your requirements.This is but a brief overview of the Raceline range ofspecialists parts for the Ford Zetec engine. For fulldetails and prices, please consult the full Racelinecatalogue, available on request.The wet sump pan has recently been modified so it canbe used in any inline Zetec installation, with any Fordgearbox, and with the starter motor on either side to suit.Also available is our alternator mounting kit, which boltsto the sump unit and locates the alternator low on the lefthand side of the engine, designed to fit the Caterhamchassis but suitable for other installations too. These special parts come as part of Raceline's tuning packages, butthey may also be purchased individually if required.Raceline - if you want the cheapest, you'd best look elsewhere: but if youwant the best, you know where to come.Raceline Cars Limited, 2 Henley Park Farm Cottages, Pirbright Road, Normandy,Nr Guildford, Surrey, GU3 2AE.Tel: 01483 811978Fax: 01483 810801

Cam follower – standard 16 10.92 Large hydraulic cam follower – 32mm 16 14.95 Cam pulley – standard 2 21.50 RACELINE adjustable vernier pulley kit – pair 1 140.00 Cam pulley bolt 2 1.19 Cam belt 1 25.36 Cam belt tensioner pulley 1 25.2