Started work on my 2001 ZX2 MTX | Ford Escort Owners Association (FEOA)
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Started work on my 2001 ZX2 MTX

Discussion in 'ZX2 1998-2004 2.0L DOHC' started by Defunct SR Owner, Apr 30, 2019.

  1. Defunct SR Owner

    Defunct SR Owner FEOA Member

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    My 2001 sat for almost 2 years that served as my daily driver and so I bought a 2017 Escape so I could drive to work.

    Apparently at some time a screw fell into the TB and sat there until whatever unique combination of forces allowed it to be sucked into the #3 cylinder valve. Eventually I found a 1998 head and am now attempting to install it. I am waiting for some lifter shims ordered online so I can complete the task.

    After much tribulation and several attempts to complete the head repair I think I solved the problem. The symptoms and codes (P0340 & 1504) implied poor timing and much time was spent redoing timing. After much frustration I let the car sit. Yesterday I checked the timing and it was perfect. I have a spare IAC and plugged it in and it did nothing and so I followed the wires and the white wire from the CCRM was broken in two near the main connector above the intake manual and installed a splice. I also repaired the throttle cable adjustor as the plastic clamping device lost some of its elasticity to clamp by using a wire zip tie that is held in place by the OEM spring. I had to leave and will test later today...(5/22/2019)

    I also fabricated a new header using the tubular Focus exhaust manifold. I cut off the Focus flange and used a piece of mandrel bent tube to make the offset down pipe and used a Napa exhaust flange to connect to cat. We'll see how it works when the head is installed. It still should be better than the old cast iron manifold.
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    Last edited: May 22, 2019
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  2. Defunct SR Owner

    Defunct SR Owner FEOA Member

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    After two years of sitting the 2001 is running!!! Two things remain, first is a new serpentine belt and then an oil change. CEL on the VCT which I hope the oil change will remedy. The car still pulls strong (MFactory & Fiddy) as it use too. I will also Sea Foam the engine tomorrow.
  3. Defunct SR Owner

    Defunct SR Owner FEOA Member

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    2001 ZX2 MTX Black.

    Before I came into possession of my current S/R ( I was an original owner of a 2000 S/R that was totaled in an accident-hence "Defunct SR Owner"), I purchased this car from a Ford Dealer in 2006 with 35,000 original miles miles. Over time I convert it into an S/R to include the rear S/R badge. The only S/R option missing is the door decals. In time I removed the S/R intake and experimented with different intake configurations to include my own design of ram air. I currently use a modified MMI configuration.

    The car has body damage to the rear passenger quarter from an accident that needs to be repaired.

    I also removed the factory AC which freed up a lot of space for more modifications and allowed me to relocate the coolant overflow from the firewall to the passenger fender as used on the Escort, and makes accessing the alternator so much easier.

    In addition to the S/R package (NGPO S/R PCM) I added Trubendz 2.25 inch stainless steel exhaust to which I recently added the modified Focus exhaust manifold. Other modifications include: MFactory LSD & Aluminum Fiddy, trunk mounted battery, Esslinger UDP, Powermaster Alt. ODP, Ford Racing Wires, Leather S/R seats and 17” rims and tires.

    My next modification will be the Focus SVT intake system to which I have all of the components. Once the SVT intake is working properly I intend to supercharge the car with the Mahle Powerworks supercharger I bought a few years back.

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    Last edited: May 6, 2019
  4. Defunct SR Owner

    Defunct SR Owner FEOA Member

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    IMG_0496.JPG I repaired the body damage to the right rear bumper cover and rear quarter, before:
    After:
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    An interesting side note, if you have ever had to remove/install a rear bumper cover you find the studs can break. The bolts are installed in pairs that are held together by plastic to ensure they align with the holes; in other words they are joined together with plastic and cannot be installed separately. Ford installs them on the internal reinforcing sub-member and then bond the sub-member to the bumper cover. The access hole to the studs makes it almost impossible to install a new stud set. To overcome this problem I used two 8mm flange nuts and two 3/4 diameter rare earth magnets. Place the bumper with the holes facing up. Set the 8mm nuts in the matched holes and place the magnets on the nuts. I used long nose pliers and positioned the stud set inside the access hole and near the holes. The magnets attract and align the studs with the nuts. Gently lift the nuts and the stud follow thru the holes, hold in place and rivet into place.
  5. Defunct SR Owner

    Defunct SR Owner FEOA Member

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    I also reassembled and cleaned the interior
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    Its been awhile since my last post even though I've made some attempts to clear the codes...all that remains is P0340.

    It starts well, idles well, accelerates well, does not die at stop signs...drive home and turn off the key-restart the car and the code reappears even thought the car runs fine.

    Today I removed the engine harness to ensure it is sound. I removed the but splice (next to the main connector on the IM) on the white wire to the IAC and soldered the wires and sealed it with heat shrink tube. I did a continuity check of both CP sensor wires and get 00.0 omega.

    I suppose a continuity check from the main connector to the PCM is next...
    Last edited: Jun 24, 2019

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