Engine – Part 1

Now it’s time to start the mods to the Zetec. The first few minor jobs are the removal of the inlet and outlet manifolds in preparation for the install of the GBS units.
First to be removed was the fuel injectors and fuel rail, followed by the manifold itself. 

You can see in the photo the cut-down manifold from GBS at the bottom of this picture. They have a jig to cut down the original inlet manifold to this size. I will return the old/full manifold back to GBS this week when I go up for a quick visit. I want to talk through the engine install before I start in earnest.

Each of the gaskets has to be transferred to the GBS cut-down version before it is installed once more along with the fuel rail and injectors.
The IAVC is also mounted on the old manifold. I have decided to remove it and try and use it with the Emerald ECU and the GBS prototype I purchased from Richard Lincoln. Richard originally bought it from GBS, but then decided to design and build his own. I am not going to do anything with it at the moment but will keep it ready for install when the time comes.

Here is the engine with the new manifold installed. I have taped up the inlets to prevent anything getting in there that shouldn’t.
Finally, the exhaust manifold needs to be removed. I am not sure if GBS can recycle this in a similar way to the inlet manifold. I will take it up with me and find out. The heat shield can be re-used along with all of the fixings. Again I have taped the port openings. This photo also shows the installed GBS breather blanking plate which replaces the Ford breather unit.