Zetec FAQ once again!

[Ness1216]

Specifications
Engine Type - 2.0L Zetec I-4 iron block, aluminum head
Valvetrain - DOHC, 4 valves per cylinder
Valve Diameters (Int/Exh) - 1.260/1.100
Bore/Stroke (in/mm) - 3.339" x 3.465" (84.8 x 88.0)
Displacement (cu in/cc) - 121.3/1988
Connecting Rod Length - 5.3618"
Main journal Dia. - 2.2831"
Rod Journal Dia. - 1.8465"
Crankshaft Center Line to Deck - 8.378"
Compression Distance Pin to Top of Piston - 1.3012"
Compression Ratio - 9.6:1
Horsepower @ rpm - 125 @ 5500
Torque (lb-ft) @ rpm - 130 @ 4000
Recommended Fuel - 87 octane
Fuel System - Sequential multi-port electronic fuel injection
Oil Capacity - 4.5 quarts


Cat-Back Exhausts
Will improve whole powerband, will increase loudness.

Trubendz - The only company to make a Zetec Cougar kit, available in different sizes and mufflers.

Also any Duratec kit can be used but will need some modifying where it bolts to our flange.


Race Headers
Will drastically improve powerband in upper powerband, and moderate in lower powerband. Will also drastically increase engine noise.

ZXTuner - 4-2-1 design. Involves removing Catalytic Converter which is illegal in the United States but only matters if you have emissions testing. Ceramic Coated and comes with MIL eliminators.

Header install how-to


Shorty Headers
Will improve upper powerband a little.

None available, any Zetec one will work but you will need a custom flange and downpipe to mate to your exhaust.


Underdrive Pulleys
You can expect slightly better acceleration and quicker engine response with one of these. Some have had major problems with them while others havee not. Takes away harmonic balancer and can cause vibrations in the crank. Some have had them for 100,000 miles + and have had no problems.

Esslinger - Crank Pulley

ZXTuner - Crank Pulley

Focus Sport - Crank Pulley

Focus Central - Crank and Water Pulley

Ford Racing - Crank Pulley

AEM Alternator UDP - Only underdrives alternator (not recommended for those with stereo systems.)

AFX - 3 pc. pulley


Throttle Body
Will increase throttle response greatly, very little to no power gain.

Basically have 2 options, one is to send it to Buckshot Motorsports to optimize it

Or, there is the option of a Focus Central 65mm Throttle Body, I have in my possesion a Focus Throttle Body that is identical to mine, but I have been unable to find which model Focus it came off of so I have not been able to tell which one works.


Intakes
Will improve powerband above ~3500, will increase engine noise.

CTA Motorsports - a good intake, easy to install but a horrible elbow design coming off the throttle body. Silicone coupler there is under stress and prone to rip. Elbow can also rub against hood. Other than that, flawless. Comes with 3" piping and a filter.

Weapon R - a good intake too, elbow design has no problems, but some have had problems with the filter. Some start deteriorating and can get sucked into the engine. Other than that, flawless.


Pistons
For when you need a stronger engine, or want to change compression.

JE

Focus Central

There are a lot more options to choose from as well.


Rods
To strengthen the weak line of the engine.

Crower

Eagle

As with pistons,a a few more choices available.


Coil Pack and Wires
Will not really add any power but will smooth idle and acceleration.

Vitek Wires

Ford Racing Wires - 9mm wires

Magnecor Wires - 8.5mm wires

Accel Coil Pack

MSD Coil Pack


Spark Plugs
Need these to make engine work. Some work beter than others.

Autolite Double Platinum APP5344

Motorcraft 417FE

Motorcraft AZFS22C (colder)

Denso Iridium ITV16

NGK 2467

Champion Double Platinum 7437


Intake Porting
You hear a lot of Focus owners wanting the early 2k intake manifolds... Reason is they were cast as 1 piece then, and are now done with 2 piece. Good news is that both 99-00 (not sure about 01-02) have the early design that flows better. Now to port this manifold you need to get out the dremel with a grinding bit and port the runners to just before where the gasket o-rings are. Just make it more smooth and open. Also if you do anything throttle body wise you should port-match the top opening of the manifold.


Adjustable Cam Gears
These help fine tune cam timing.

Esslinger
OBX
Focus Central
Focus Sport
Fidanza
Ford Racing
Unorthodox


Camshafts
Will drastically change powerband. Lose some low end to gain a lot of top end.

Web Cams

Any Focus Intake Cam will work, Exhaust will not work due to VCT design.


Valvetrain
Crower offers Titanium Valves and Reatainers to be able to rev higher without valve float.


Motor Mounts
Same as the duratec equipped cars, can use Energy Suspension inserts up front. Fill the rears with Polyurethane.


Differences between Non-VCT Zetecs and normal Zetecs
So far I have found this:

Coolant Temperature Sensor is mounted differently.
Cam Position Sensor is on exhaust side on VCT motors, on intake for normal zetecs. Different Part numbers.
Shortblock is same part number. Same block.
Head gasket same part number as SVT Focus, Fel-pro lists universal gasket for all zetecs.
Same Head Bolts
VCT exhaust cam is larger diamter than that of non VCT Zetec cam.
Cannot use Cougar intake cam on Focus due to cam having no key for cam position sensor.
More to come, hopefully not, should be doing FR Head swap soon.


Stroker Kits
Crower makes Stroker Kits to make your zetec any size up to 2.3l, asdverse effects may include, but not nessecarily lowr Rev limit.


Will have more to come soon...

[azbobbybooshay10]

This one probably isn't too far down, but since its an FAQ, I'll bump it up so that it can be re-stickied.

[Seawulf]

Sorry for the long absence, but my hard drive crashed and it took a while to get setup and then I also switched email programs so I could have missed the email to switch addresses, so I kept going to the old site that wasn't there and just thought the forums were down again.

I'll sticky this now.

[peanuts_parts]

U should add a lot to that.

Eletronics;
SCT tunes
enlarged MAF, wouldn't go any bigger than 70MM though.
"black box" from ZXtuner or POTS mod..
disable VSS-(vechile speed sesnor)= no governor! but will cause check engine light to come on, so just put on a toggle switch.

Intake manifolds;
FC intake manifold-(very rare though)
Focus SVT "DSI"-(dual Stage Intake manifold) great for N/A cars, but a lot of factors for conversion.
Ford Racing intake manifold-will have to re-dril bolt for TB and to fit flushly against the head.
Or make ur own.........

Throttle body;
FC 65mm
Jackson Racing 65mm
BBK 65mm
all will work, just need the TPS from a earlier Focus and spice the wires..

Spark wires;
Nology wires.

Fuel pumps;
Stock Focus, SVT Focus, or Mustng V6 fuel pump. Will provide better fuel pressure for high fuel demands..

Fuel Rails;
STR (can be converted from a Focus, email for details)
ealry ZX2 with Fuel pressure snout for N02 hook up.

Adjustable Cam Gears;
AEM
Crower
STR

Lighten Flywheel;
Fidanza

Clutches;
SPEC
(many more just can't remember)

Valvetrain;
Ford Racing will fit
Crower
Esslinger
Ferra

After market ignitions;
MSD DIS-2

Ported head options;
Esslinger
Gude-(they have a head package that will also include better cams, same as Esslinger)
Focus Sport
Ford Racing
(now to install a non-VCT head on a VCT engine, u will need to get new cams, a Focus cam sensor, and some VCT tuning...)

[Sham]

::Edit::didnt notice my bad

this is gold

[peanuts_parts]

ur welcome

[james99]

Originally Posted by Shamcooga99

bump

this is gold

no need to bump it, it's stickied itll always be at the top.

[Great1h98]

does anyone know where to find the throttle body for the i4 cougar... a 65mm body off a focus, but which one is the proper fit?

[peanuts_parts]

Ebay, but throttle cable bracket will need modification

[bdiddy]

hey ness, don't forget to add that VCT adds a ton of hp to the coug