Ford Zetec 2.0L Non-Ducted Nose Modifications

The schematic diagram shows a new junction welded in to the alloy pipe running between the radiator bottom hose and the water pump inlet. This junction is connected via a new alloy pipe to thermostat housing bypass outlet. The new junctions and pipe work have anti blow off ends formed by running a weld around the circumference of the pipe.

The heater connections are not modified

(Click on the diagram for a full size picture)

Radiator bottom hose connections (Modified)

The diagram, above left, shows the modified alloy pipe. It is not to scale and is dimensionless to allow the modification of the pipe to suit the vehicle. On our car there was sufficient room to weld a second junction to the pipe, leaving suitable clearances to fit the rubber hoses. Anti blow off ridges were formed by welding around the circumference of the pipe (Click on the diagram for a full size picture)

The photograph, above right, shows the modified bottom hose alloy pipe on situ,. The right hand junction is connected the heater and the left hand junction is connected to the new bypass pipe.

A suitable bypass pipe can be manufactured to the approximate dimensions as above. Made from 16mm alloy or copper tube with a bend formed at each end. The downward end, which connects to the modified alloy bottom pipe is formed at 15˚ from the vertical or 75˚ with respect to the horizontal junction, which connects to the thermostat housing. Anti blow off ridges can be made by running a weld round the circumference of the pipe. If copper pipe is used suitable bends can be made from “Yorkshire” solder fittings (Click on the diagram for a full size picture)

The photograph shows the new bypass pipe connected to the modified bottom hose alloy pipe and routed alongside the heater pipe. The bypass pipe and heater pipe are secured together, at regular intervals, using pipe / wiring clips available from Vehicle Wiring Products.

The Diagram (above) shows the Radiator top hose connections modified. An alloy pipe, “J”, from the radiator top hose to the main thermostat-housing outlet this pipe has the junction that was connected to the thermostat bypass. This must be blanked off and sealed. This pipe also contains the thermostatic switch for the fan. If you have a “red top” switch Ford FINIS No: 7001614, replace it with an “orange top” switch Ford Finis No: 7001611 (Click on the diagram for a full size picture)

The photograph above right shows the connections to the Thermostat housing. The thermostatic switch (blue plug) can be seen, fitted in to the pipe from the main thermostat-housing outlet. Beneath this pipe is the rubber hose connecting the new bypass pipe to the thermostat bypass outlet. The blanked off connection in the main pipe was made using a ½” BSP adapter and an M10 Bolt. The pipe was tapped to ¼ ”BSP thread and the adapter was, internally, tapped to match the M10 bolt. The ¼ ” BSP adapter was wrapped in PTFE tape to seal it and screwed in to the pipe. The M10 Bolt was similarly wrapped in PTFE tape and screwed in to the adapter. This arrangement has proved watertight

The Photograph (above left) shows the coolant pipe running down the Left had side of the body. The alloy pipes are fastened together using pipe clips to provide a neat and secure installation. ((Click on the diagram for a full size picture)

Diagram 48 (above right) shows that the heater connections are unmodified. However due to the substantially smaller Westfield expansion tank, to ensure that there is sufficient expansion space in the header tank, the system should be filled to half way between the minimum and maximum marks on the tank

Ford 2.0 L Zetec Ducted Nose, Modifications.

The modification of the ducted nose is the same as non-ducted nose. Just the layout detail is different, caused by the radiator being fixed to the nose cone and not the chassis. The diagram (above left) shows the bottom hose connections with a new junction welded to the alloy pipe as before and connected to the water pump inlet. A rubber hose connects to the new junction to the alloy bypass pipe. Which is connected at the opposite end, to the thermostat housing bypass outlet (Click on the diagram for a full size picture)

Similar to the non ducted nose installation the alloy pipe connecting the Radiator top hose and the main thermostat housing outlet has the redundant junction, formerly used for connecting to the thermostat bypass (above right). This must be blanked off and sealed

The Thermostatic switch for the fan is mounted in the radiator. If you have a “red top” switch Ford FINIS No: 7001614, replace it with an “orange top” switch Ford Finis No: 7001611 for normal fan operation. (Click on the diagram for a full size picture)

The heater connections are unmodified.

The diagram (left) shows again the new thermostat bypass pipe and the blanked off junction in the pipe to the radiator top hose. (Click on the diagram for a full size picture)

Because of the smaller size of the Westfield expansion tank. To ensure that there is sufficient expansion space in the header tank, the system should be filled to half way between the minimum and maximum marks on the tank