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Discussion Starter · #1 ·
Anyone have the how to for this?

anyone have dimensions for porting the head?

Seems that replacing the pipe from the injectors to the air cleaner could help with a larger pipe could help, I guess the bump on the stock one is a resonator at some RPM, would it's absence hurt performance?

Any other minor mods that will help will be appreciated!

Thankx
ROARRR
 

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I understand setting the cams needs to be done with adjustable components and working on a dyno.

There are a lot of good pictures and info on porting the ZETEC at Passionford (a website from Great Britian). The general consensus on the heads is that the ports just need to be cleaned up. The main work is to open up the bowls and unshrould the valves on the chamber side. I understand this should be good for about a 10% increase in power.

For bolt on mods:

Underdrive crank pulley
Iceman Intake or Keman mod to stock intake
Open up the air filter housing inlet to 3inch and plumb back to cold air ( original fender location will do)
Pacesetter headers or if you can find better models that are no longer in production.
Disconnect knock sensor.

Just the above will really increase midrange and top end power. ( this is what I have done so far). I just did the knock sensor and I seem to have picked up about 3 mpg. I still need to run some test tanks.
Also you may want to disconnect the A/C compressor. Stupid Ford has it running on every setting of the climate controls except vents only.

High flow cat
2 1/4 inch trubenz exhaust.
Swap in better cpu from other zx2 for better engine management
If a 98- 99 1/2 engine ( single hole injectors), get better 4- hole injectors for later zetec, However, with these mods you probably should get slightly larger injectors, which will hopefully still work with the stock cpu settings.

Cooler for auto trans
LSD for manual trans.... there are other upgrades you can do to manual trans.

These are the mods I have or have planned. At this power level ( probably 150 to 160 hp at crank, with no head porting) it may be helpful to have a larger throttle body.
 

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Anyone have the how to for this?

anyone have dimensions for porting the head?

Seems that replacing the pipe from the injectors to the air cleaner could help with a larger pipe could help, I guess the bump on the stock one is a resonator at some RPM, would it's absence hurt performance?

Any other minor mods that will help will be appreciated!

Thankx
ROARRR
from your post I assume you are fairly new to the ZX2, so here goes a list from an old-timer that recently re-joined the forum...
These are my suggestions on where to start modding, they are inexpensive, and easy mods that give good results for both HP and fuel economy.
For the air intake if it's still factory, remove and replace the upper resonator with a straight PVC pipe of the same length, remove the resonator below the air filter housing, cut the air filter housing at the centerline of the mount closest to the fender, then fit a 4inch to 3 inch black PVD adaptor into the air housing, trim the gasket that is in the inner fender to fit the adaptor this is known as the keman mod.
next - replace the paper filter with a cloth filter that can be cleaned, the car will breathe better.
next replace the restrictive exhaust system with one that flows better - for ATX do not go larger than 2.25 inch diameter pipe, for MTX do not go over 2.5 inch pipe.
Adjusting the cams can be done through software for the exhaust cam, suggested no more than 2 degree adjustment accross the board. the intake cam can only be adjusted mechanically with an adjustable cam gear.
next inexpensive mod I would suggest is a under drive pulley for the crank shaft, and an overdrive pulley for the altenator, this combo will cause the A/C and power steering to use less HP, while keeping the altenator operating at the correct RPM.

as for porting the head, JohnP. from Teamzx2.com would be the best person to contact, tho with TeamZX2.com being down permanently, I don't have his contact info.
 

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I understand setting the cams needs to be done with adjustable components and working on a dyno.

There are a lot of good pictures and info on porting the ZETEC at Passionford (a website from Great Britian). The general consensus on the heads is that the ports just need to be cleaned up. The main work is to open up the bowls and unshrould the valves on the chamber side. I understand this should be good for about a 10% increase in power.

For bolt on mods:

Underdrive crank pulley
Iceman Intake or Keman mod to stock intake
Open up the air filter housing inlet to 3inch and plumb back to cold air ( original fender location will do)
Pacesetter headers or if you can find better models that are no longer in production.
Disconnect knock sensor.

Just the above will really increase midrange and top end power. ( this is what I have done so far). I just did the knock sensor and I seem to have picked up about 3 mpg. I still need to run some test tanks.
Also you may want to disconnect the A/C compressor. Stupid Ford has it running on every setting of the climate controls except vents only.

High flow cat
2 1/4 inch trubenz exhaust.
Swap in better cpu from other zx2 for better engine management
If a 98- 99 1/2 engine ( single hole injectors), get better 4- hole injectors for later zetec, However, with these mods you probably should get slightly larger injectors, which will hopefully still work with the stock cpu settings.

Cooler for auto trans
LSD for manual trans.... there are other upgrades you can do to manual trans.

These are the mods I have or have planned. At this power level ( probably 150 to 160 hp at crank, with no head porting) it may be helpful to have a larger throttle body.
THANKZ!! That's exactly
51371
what I need, This is my driver, I have others to race but I want to optimise it for me! Ford has to make it so itt'le be happy in Texass and Alaska and driven by my grandma and me~~I'm old school so am struggling with the computerisation but LOVE this car!
 

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from your post I assume you are fairly new to the ZX2, so here goes a list from an old-timer that recently re-joined the forum...
These are my suggestions on where to start modding, they are inexpensive, and easy mods that give good results for both HP and fuel economy.
For the air intake if it's still factory, remove and replace the upper resonator with a straight PVC pipe of the same length, remove the resonator below the air filter housing, cut the air filter housing at the centerline of the mount closest to the fender, then fit a 4inch to 3 inch black PVD adaptor into the air housing, trim the gasket that is in the inner fender to fit the adaptor this is known as the keman mod.
next - replace the paper filter with a cloth filter that can be cleaned, the car will breathe better.
next replace the restrictive exhaust system with one that flows better - for ATX do not go larger than 2.25 inch diameter pipe, for MTX do not go over 2.5 inch pipe.
Adjusting the cams can be done through software for the exhaust cam, suggested no more than 2 degree adjustment accross the board. the intake cam can only be adjusted mechanically with an adjustable cam gear.
next inexpensive mod I would suggest is a under drive pulley for the crank shaft, and an overdrive pulley for the altenator, this combo will cause the A/C and power steering to use less HP, while keeping the altenator operating at the correct RPM.

as for porting the head, JohnP. from Teamzx2.com would be the best person to contact, tho with TeamZX2.com being down permanently, I don't have his contact info.
I understand setting the cams needs to be done with adjustable components and working on a dyno.

There are a lot of good pictures and info on porting the ZETEC at Passionford (a website from Great Britian). The general consensus on the heads is that the ports just need to be cleaned up. The main work is to open up the bowls and unshrould the valves on the chamber side. I understand this should be good for about a 10% increase in power.

For bolt on mods:

Underdrive crank pulley
Iceman Intake or Keman mod to stock intake
Open up the air filter housing inlet to 3inch and plumb back to cold air ( original fender location will do)
Pacesetter headers or if you can find better models that are no longer in production.
Disconnect knock sensor.

Just the above will really increase midrange and top end power. ( this is what I have done so far). I just did the knock sensor and I seem to have picked up about 3 mpg. I still need to run some test tanks.
Also you may want to disconnect the A/C compressor. Stupid Ford has it running on every setting of the climate controls except vents only.

High flow cat
2 1/4 inch trubenz exhaust.
Swap in better cpu from other zx2 for better engine management
If a 98- 99 1/2 engine ( single hole injectors), get better 4- hole injectors for later zetec, However, with these mods you probably should get slightly larger injectors, which will hopefully still work with the stock cpu settings.

Cooler for auto trans
LSD for manual trans.... there are other upgrades you can do to manual trans.

These are the mods I have or have planned. At this power level ( probably 150 to 160 hp at crank, with no head porting) it may be helpful to have a larger throttle body.
 

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I understand setting the cams needs to be done with adjustable components and working on a dyno.

There are a lot of good pictures and info on porting the ZETEC at Passionford (a website from Great Britian). The general consensus on the heads is that the ports just need to be cleaned up. The main work is to open up the bowls and unshrould the valves on the chamber side. I understand this should be good for about a 10% increase in power.

For bolt on mods:

Underdrive crank pulley
Iceman Intake or Keman mod to stock intake
Open up the air filter housing inlet to 3inch and plumb back to cold air ( original fender location will do)
Pacesetter headers or if you can find better models that are no longer in production.
Disconnect knock sensor.

Just the above will really increase midrange and top end power. ( this is what I have done so far). I just did the knock sensor and I seem to have picked up about 3 mpg. I still need to run some test tanks.
Also you may want to disconnect the A/C compressor. Stupid Ford has it running on every setting of the climate controls except vents only.

High flow cat
2 1/4 inch trubenz exhaust.
Swap in better cpu from other zx2 for better engine management
If a 98- 99 1/2 engine ( single hole injectors), get better 4- hole injectors for later zetec, However, with these mods you probably should get slightly larger injectors, which will hopefully still work with the stock cpu settings.

Cooler for auto trans
LSD for manual trans.... there are other upgrades you can do to manual trans.

These are the mods I have or have planned. At this power level ( probably 150 to 160 hp at crank, with no head porting) it may be helpful to have a larger throttle body.
I understand setting the cams needs to be done with adjustable components and working on a dyno.

There are a lot of good pictures and info on porting the ZETEC at Passionford (a website from Great Britian). The general consensus on the heads is that the ports just need to be cleaned up. The main work is to open up the bowls and unshrould the valves on the chamber side. I understand this should be good for about a 10% increase in power.

For bolt on mods:

Underdrive crank pulley
Iceman Intake or Keman mod to stock intake
Open up the air filter housing inlet to 3inch and plumb back to cold air ( original fender location will do)
Pacesetter headers or if you can find better models that are no longer in production.
Disconnect knock sensor.

Just the above will really increase midrange and top end power. ( this is what I have done so far). I just did the knock sensor and I seem to have picked up about 3 mpg. I still need to run some test tanks.
Also you may want to disconnect the A/C compressor. Stupid Ford has it running on every setting of the climate controls except vents only.

High flow cat
2 1/4 inch trubenz exhaust.
Swap in better cpu from other zx2 for better engine management
If a 98- 99 1/2 engine ( single hole injectors), get better 4- hole injectors for later zetec, However, with these mods you probably should get slightly larger injectors, which will hopefully still work with the stock cpu settings.

Cooler for auto trans
LSD for manual trans.... there are other upgrades you can do to manual trans.

These are the mods I have or have planned. At this power level ( probably 150 to 160 hp at crank, with no head porting) it may be helpful to have a larger throttle body.
from your post I assume you are fairly new to the ZX2, so here goes a list from an old-timer that recently re-joined the forum...
These are my suggestions on where to start modding, they are inexpensive, and easy mods that give good results for both HP and fuel economy.
For the air intake if it's still factory, remove and replace the upper resonator with a straight PVC pipe of the same length, remove the resonator below the air filter housing, cut the air filter housing at the centerline of the mount closest to the fender, then fit a 4inch to 3 inch black PVD adaptor into the air housing, trim the gasket that is in the inner fender to fit the adaptor this is known as the keman mod.
next - replace the paper filter with a cloth filter that can be cleaned, the car will breathe better.
next replace the restrictive exhaust system with one that flows better - for ATX do not go larger than 2.25 inch diameter pipe, for MTX do not go over 2.5 inch pipe.
Adjusting the cams can be done through software for the exhaust cam, suggested no more than 2 degree adjustment accross the board. the intake cam can only be adjusted mechanically with an adjustable cam gear.
next inexpensive mod I would suggest is a under drive pulley for the crank shaft, and an overdrive pulley for the altenator, this combo will cause the A/C and power steering to use less HP, while keeping the altenator operating at the correct RPM.

as for porting the head, JohnP. from Teamzx2.com would be the best person to contact, tho with TeamZX2.com being down permanently, I don't have his contact info.
THANKZ!! That's exactly
51371

what I need, This is my driver, I have others to race but I want to optimise it for me! Ford has to make it so itt'le be happy in Texass and Alaska and driven by my grandma and me~~I'm old school so am struggling with the computerisation but LOVE this car!



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#5 · a moment ago


I understand setting the cams needs to be done with adjustable components and working on a dyno.

There are a lot of good pictures and info on porting the ZETEC at Passionford (a website from Great Britian). The general consensus on the heads is that the ports just need to be cleaned up. The main work is to open up the bowls and unshrould the valves on the chamber side. I understand this should be good for about a 10% increase in power.

For bolt on mods:

Underdrive crank pulley
Iceman Intake or Keman mod to stock intake
Open up the air filter housing inlet to 3inch and plumb back to cold air ( original fender location will do)
Pacesetter headers or if you can find better models that are no longer in production.
Disconnect knock sensor.

Just the above will really increase midrange and top end power. ( this is what I have done so far). I just did the knock sensor and I seem to have picked up about 3 mpg. I still need to run some test tanks.
Also you may want to disconnect the A/C compressor. Stupid Ford has it running on every setting of the climate controls except vents only.

High flow cat
2 1/4 inch trubenz exhaust.
Swap in better cpu from other zx2 for better engine management
If a 98- 99 1/2 engine ( single hole injectors), get better 4- hole injectors for later zetec, However, with these mods you probably should get slightly larger injectors, which will hopefully still work with the stock cpu settings.

Cooler for auto trans
LSD for manual trans.... there are other upgrades you can do to manual trans.

These are the mods I have or have planned. At this power level ( probably 150 to 160 hp at crank, with no head porting) it may be helpful to have a larger throttle body.
SUPER info--will keep me off the streets for a while~~ This car is new to me so I have lots to learn about it!

Where do i look for the KEMAN intake mod?

Can I interchange a head that doesn't have the sensor at the top front assuming that the sensor can be put elsewhere?
 

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Just look up Keman mod on a google search and some sample should pop up. Also, I think some members here have some iceman intakes available.
I haven't gotten that deep into the motor, so I don't know about head swapping. I believe the 98-991/2 heads can't be swapped into later zetecs.
 

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Thanks for your thots! I'll check that further, My car's head has a sensor at the top front between the cams I have other engines that don't! I think it somehow controls the VTEC but the others also have it W\o the thing~~
 

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I'm looking for the PCM or the FPDM, found a box behind a metal part of the right side of the trunk it has many wires including a LARGE wire going forward, it doesn't look like the one on the you tube video, where are these critters?
 

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My zetec is in my 98 Wagon....I did a swap with a good mechanic in CA and then drove it home to Chicago. Another good upgrade for handling is the Poly urethane kit for the front control arms, sway bars, and rack mount. Getting the large rear bar from the 2nd gen wagons ( or maybe the GT ...21mm IIRC) really makes the handling much more neutral. I think the stock bar is only 13 mm, I'm pretty sure 19 mm and 21 mm are available from different models. On my wagon ( 21mm bar) with no throttle when pushed to the limit it will slide sideways with no rotation. Rear disc brakes do wonders for stopping power ( escort GT and rare 3rd gen escorts). Wheels off a early Mazda Miata are supposed to be a direct fit .. same bolt pattern, center hole and offset. I've got a set of 4- 16" x 6 1/2" waiting for me to pick up in CA on my next trip which will be fitted with 205-45R16. Attached is the modified air filter housing...I've got to find a way to seal it better to the inner fenderwell to ensure only cold air is getting in.
51374
51375
 

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The only thing I'd add is to keep a lightened flywheel in mind the next time you have to replace the clutch. When my clutch was on it's way out I replaced it with a stage 2 clutch I bought off of Ebay. The stock level clutch would have worked just fine at the power level I'm at but I wanted to have it installed since I was thinking I may up the HP through either FI or head work, etc. The stage 2 clutch consists of a kevlar friction plate and a heavy duty pressure plate. The clutch feel isn't that much off from the stock one with only a slightly heavier pedal. Since I was replacing the clutch I decided to also replace the flywheel with a lightened one from Fidanza. The results were much more crisp throttle and a bump in torque. Not much gain on the HP side but my aim has been to make the car quicker rather than faster for street fun!

John
 
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