Hello! Your friendly moderator ProjectFocusFast is here to answer all your questions about modding your Zetec-powered Focus.
I'm assuming you have identified that your car has a Zetec, and not a Duratec or SPI or Duratec PZEV engine. If you're unsure, it's pretty simple. If the valve cover is black plastic (or if it's an early 2000 and is metal) and says "Zetec" or "DOHC Zetec" or "16v Zetec" it's a pretty safe bet we're in business!
So you know you have a Zetec, and want to get started modifying it to get a little more "oomph". First I should warn you that the automatic transmission will not handle much more than stock. So if you're thinking about going with any kind of forced induction, you better have a manual, or some serious bucks to spend on souping up the trans too.
Natural Aspiration
If you plan to keep your car daily drivable and keep great gas mileage, there is no better choice than keeping it natural. Building an NA motor is fairly simple with a Zetec- it's a solid base and it takes fairly well to bolt on modifications.
Stage 1
Stage 1 for an NA motor is always "opening it up".
- Short ram intake; there are a few on the market, but beware of eBay ones that don't have any provisions for the MAF sensor. OR you can simply replace the stock airbox with cone filter, not quite as good but it works.
- Exhaust; there are many brands. You want mandrel bends, and with NA I'd recommend no bigger than 2.5". I'd say eBay is OK here, just ask a few buyers first if they've had any problems.
- Header; The SVT header is the best header there ever is or was for the Zetec. If you can get a complete SVT system with header, flex section and catalytic converter, all the better! Beware of "street headers" or "shorty headers" as they really don't flow much better than stock. And ALWAYS replace the cat and flex section to match the header- otherwise it's pointless!
- Underdrive pulley; again many brands. I'd stick with a solid brand like Massive or AEM. You can't go wrong here. I've seen people gain quite a bit with just this one simple mod!
- Plugs + wires; a good Iridium plug (Denso or NGK) and some good name-brand plug wires will help any engine.
Stage 2
Stage 2 takes over where stage 1 left off, adds a lot more power and is a big step towards some real power!
- Chip / programmer; More timing, more fuel... more power! SCT makes a nice programmer, or take it to a reputable shop and let them set you up.
- Head work; The Zetec head is pretty restrictive, either get a Ford Racing or FocusSport head, or have yours professionally ported, polished, and a valve job. Maybe get a few thousandths shaved off to raise compression. NOTICE: The Zetec head is EXTREMELY hard to work with. Take this thing to a pro!
- Intake manifold; There's only 2 good ones- the early 2000 manifold and the Ford Racing manifold. Manifold code for the early 2000 is W54E.
- Cam gears; This requires some dyno time- on a REAL DYNO! Don't trust the butt dyno here.
Stage 3+
How fast do you want to go?
Cams? More compression? Catless exhaust? SVT head? Rev to 9000? This comes down to wallet size and streetability.
Nitrous Oxide
The reason I list nitrous right after NA is because you'll still want a lot of the NA mods. All of NA's stage 1 is applicable to nitrous. A good intake manifold and cam gears, and nitrous cams will help you too. You want to go with a "wet" system! Don't rely on your stock fuel system to add enough fuel through the injectors. A wet system is a lot safer- and you can get a lot more power out of it.
Stage 1
NA stage 1 PLUS:
- Wet nitrous system. The stock engine and fuel system will handle up to a 75 shot. Nitrous Express "import kit" is a good bet.
- Colder spark plugs.
Stage 2
Nitrous stage 1 PLUS:
- Upgraded fuel system. Convert to return system, adjustable fuel pressure regulator, larger diameter fuel lines. With this setup, I've seen a 100 shot, and I'd say a 125 shot is possible (not for too long though). Colder plugs to match.
Stage 3+
Super spray. Stage 2 PLUS:
- Direct Port nitrous system.
- Engine internals (stronger rods + pistons) so you can handle more spray
- "Staged" system for less wheelspin
Supercharging
Supercharging is a great "install and go" mod- it's an easy way to add a bunch of horsepower really fast, and all the way though the powerband! No "turbo lag" or need to refill the bottle.
Stage 1
This sets the footprint for your engine.
- PowerWorks supercharger system
- Full (header + back) exhaust. 2.5-3"
Stage 2
Step it up! More power, less streetability. Stage 1 PLUS:
- Smaller pulley on supercharger.
Stage 3+
Boost to the MAX!
- Even smaller pulley on S/C or larger crank pulley (or both!)
- Tuning software or stand-alone ECU
- Fuel system overhaul (return system conversion, larger lines, AFPR)
- Engine internals (rods / low comp pistons)
- Oil pump (to rev to 8k+!)
Turbocharging
There's more than enough turbo advice out there, but here's my two cents anyway.
Stage 1
Basic turbo system
- TRUSTED name brand turbo system. Turbo Tom, FocusSport, I think Massive makes a turbo kit too.
Stage 2
Next steps towards more power! Stage 1 PLUS:
- Intercooler
- Boost Controller
- Tuning software
- Fuel system upgrade (bigger lines and injectors, fuel rail, convert to return system and get AFPR)
Stage 3+
Custom turbo setup!
- Large turbine (T3/4 should suffice here)
- SCT Pro Racer software or Megasquirt tuning system
- Big ol' honkin' intercooler
- Oil pump upgrade so you can rev higher
- Engine internals (rods and low-comp pistons)
- Complete fuel system overhaul
- Cams and head work
____________________ Project FocusFast
'06 ZX3- Intake, exhaust, mount
'01 ZX3- Salvaged, SOLD
'01 ZX3- Repo'd several years ago
'80 RX7 SA- Where the f*** did THAT come from?
I agree with PFF......mostly. My car is a ZX2 stage 2. The only thing I'd say differently is to save your money on the chip unless you have an automatic. On the mtx cars, they make almost no noticible difference at all. They do remove the govenor to increase top speed, bt unless you're going to regularly drive 130 mph plus, forget it.
____________________ If you can't read this, you're illiterate.
where can i find an SVT header, flex section, and cat for my ZTS? a while back you said something about having to modify the ZTS head for the SVT header, im still in the dark about that. any instructionson how to do this? how much for that setup, how much will i have to spend to make it fit? do you know of anyone that has this setup for sale? or is it time for a trip to the salvage yard? any suggestions or solutions will be helpful.
There is no modification required. The SVT header is a direct bolt on to the regular Zetec. As for finding one? You're on your own there! Check classifieds on Focus boards, check junk yards, check http://www.car-parts.com (local junkyard and parts finder) and if all else fails, check the stealership.
____________________ Project FocusFast
'06 ZX3- Intake, exhaust, mount
'01 ZX3- Salvaged, SOLD
'01 ZX3- Repo'd several years ago
'80 RX7 SA- Where the f*** did THAT come from?
I belever the SVT header needs to be modified a bit due to the 2 differant systems used between the SVT and regular Zetec. I think an EGR tube needs to be added to the SVT header unless you get a chip to disable EGR and block off the EGR port on the motor.
Oh ok that might be. But blocking the EGR is so simple... if you don't mind a check engine light, blocking the EGR requires nothing more than an empty soda can, a tin snips, a socket set and 15 minutes.
____________________ Project FocusFast
'06 ZX3- Intake, exhaust, mount
'01 ZX3- Salvaged, SOLD
'01 ZX3- Repo'd several years ago
'80 RX7 SA- Where the f*** did THAT come from?
