The ZVH engine is a hybrid engine comprising of a 2.0 Zetec block and CVH head.

This guide has been prepared to share the information gained in building the ZVH engines over the years. It would be good to note that a built ZVH with 10Psi boost can produce a power output of 226bhp at the wheels, 259 bhp at the engine, 260 ft/lb of torque at 5520rpm. Start with a Zetec black top engine due to the better positioning of the oil fiter and the first job is to completly strip the block, crank, rods and pistons. Water Pump Fitting a CVH water pump on the side of the Zetec block, start by placing a CVH water pump gasket on the block lining up the top left bolt hole in the gasket with the M8 hole on the block, then mark the remaining 3 holes on the block followed by marking the large center hole for the impeller. Drill out the 3 remaining mounting holes 5mm and tap the holes M6 x 1, you may break through into the water jacket when drilling these holes, just use a bit of sealant on the threads when assembling. To make the large impeller hole, line drill the marked out line then with a chisel lightly knock out the center. Next with a die grinder remove all the sharp edges. You will also have to drill out the top left mounting hole in the water pump 8mm to accept the M8 bolt that fits in the block.

Mounting the CVH 1.3 Tensioner I fit a heli-coil or a time sert to the already placed M10 hole on the top left of the Zetec block to reduce it to M8 to fit the tensioner, the front hole is carefully placed 11mm from the front of the block, this is a critical dimension, as if it is too far back it will interfere with the head bolt and 12mm down.

On the front of the Zetec block there is a breather assembly that should be removed if using the std CVH exhaust manifold. You have to use a 40mm core plug not an aluminum blanking plate as it will prevent the exhaust manifold from sealing properly on the CVH head. When the above operations are complete you can clean the block inside and out. Water Pump When bolting the CVH water pump onto the Zetec block use a spacer plate to prevent the CVH impeller rubbing on the outer cylinder wall. I also cut the back off the end of the rear slide hole on the tensioner to allow the tensioner to slide right back without interfering with the engine mount. Head Gasket I use my own design of head gasket which has a repositioned oil way and blanks off the unused Zetec oil drain holes. This is a re-usable gasket. Head Bolts I use high tensile bolts which are re-usable and 145mm long. Assemble with the thick CVH head bolt washers. Torque is 65 ft/lbs with ARP bolt lube. For the cam belt pulley/drive assembly use the pressed steel CVH inner washer followed by the CVH bottom cam belt pulley, then your choice of alternator pulley. For the CVH camshaft pully you will have to use a vernier because the Zetec block is a different height to the CVH, meaning the crank timing mark and cam timing mark are half a tooth out of alignment, this is corrected by adjusting the vernier pully. Sump Modifications

You can use either the one piece aluminum sump or the two piece steel/ali sump assembly, this decision is based on what gearbox you are running. For turbo applications you will have to fit a drain back tube for the turbo drain. Also a good sized breather/drain tube attached to the rear. ZVH Assembled