The ZX2 Guide (in progress)

[AltecZX2]

Powertrain
Drivetrain: Front Wheel Drive
Engine: 2.0L Zetec Inline-4 iron block & aluminum head Variable Cam Timing(VCT)
Valvetrain: 4 valves per cylinder DOHC (DOHC 16V)
Bore/stroke (in/mm): 3.34x3.46 / 84.8x88.00
Displacement: 121 cu in
Compression ratio: 9.6:1
Horsepower: 130@5750
Torque (lb-ft): 127@4250
Oil capacity (quarts): 4.5
Fuel tank (gallons): 12.7

Transmission - G5M (Mazda designed)
5 Speed MTX Gear Ratios
1st - 3.307:1
2nd - 1.833:1
3rd - 1.310:1
4th - 1.030:1
5th - 0.795:1
Final Drive - 4.10:1
Reverse - 3.166:1

4 Speed ATX Gear Ratios
1st - 2.80:1
2nd - 1.54:1
3rd - 1.00:1
4th - 0.70:1
Final Drive - 3.74:1
Reverse - 2.330:1

Dimensions
Wheelbase: 98.4
Overall Length: 175.2
Overall Width: 67.4
Overall Height: 52.3
Base Curb Weight (lbs) 2478
Towing Capacity Max (lbs): 1000
------------------------------------------------------------------------------------------------------------
Powertrain Control Module (PCM, ECU)
98-99 ZX2’s have a four (4) wire MAF and can only correctly use a 98-99 ZX2 PCM
(there is a wire hack to allow 99.5-03 PCM usage)
99.5-03 ZX2’s use a six (6) wire MAF and can only use 99.5-03 PCM correctly

S/R and Ford Racing PCM’s
NGP0 (1999 S/R, FR) calibration 155MPH speed limiter, added timing, refined fuel rated 10% power increase (Cali emissions)
CWQ3 (2000 S/R) minor fuel curve tweak, small addition to timing 160MPH speed limiter (45 state legal)
XHG3 (2000 S/R) same as NGP0 with less timing (same timing as CWQ3 (Cali emissions)

As of 2001 Ford started adding fuel and taking away timing from the cars via the PCM calibration, in 2003 that cars are no longer making the power they were originally rated at in 1998. 2003 codes are to be avoided at all costs, and it is recommended that if you have a 2003 ZX2 that you will get better mileage and a small power increase from moving to a 99.5-2001 PCM. If you have an original PCM in your car from 98-2001 DO NOT LET FORD UPDATE YOUR PCM.

If needed I can show an image of a CWQ3 dyno vs a GRS0 (CWQ3’s 2003 ‘updated’ counterpart) and there is a 19whp/14wtq loss.
------------------------------------------------------------------------------------------------------------
S/R Package
143hp/140tq

2000 S/R
Only 2000 produced
Iceman intake
Leather shift boot
B&M Short throw shifter
Centerforce Performance Clutch
Retuned PCM
Tokico Struts
Energy Suspension Bushings
Eibach Lowering Spring
Borla exhaust
S/R wheels: 205/55ZR15 Goodyear Eagle
Rear disc brakes
Silver gauge surround
150 MPH speedometer
Ford Blue valve cover
Available in zinc yellow, red and black

1999 S/R
Only 106 produced
Same as above either the following changes
Roush intake
Black valve cover
Escort GT wheels
Zinc yellow only
------------------------------------------------------------------------------------------------------------
Variable Cam Timing (VCT)

The exhaust cam on the ZX2makes use of a VCT system that will retard the cam up to 6* to help lower emissions as the ZX2 does not have an EGR system, as a side effect the torque is not as great as the Focus Zetec but the ZX2 has a longer power band, its also runs more aggressive cams.
------------------------------------------------------------------------------------------------------------
Parts Upgrades

The following parts can be used form other cars on the ZX2 as an upgrade.
Rear disc breaks from: Escort GT, 98+ Tracer, Mid 90’ Protégé, possibly and MX3
Rear sway bar from: Escort GT (19mm), 2nd gen Escort wagon (21mm)
Strut bars for an MX3 also fit the ZX2, and a few MX3, and Protégé suspension parts will also work.

Aside from the head, the ZX2 and Focus Zetec motors are the same. Intakes, and exhaust cams for a Focus will NOT work on a ZX2, a header will work with some fabrication. ZX2 stock cams are more aggressive than Focus cams.
------------------------------------------------------------------------------------------------------------

Knock Sensor
Unplugging the knock sensor can cause your car to run more timing and produce more power, the gain depends on the calibration of your stock PCM....this does no/little good for those running NGP0.

The vibration from the head is enough that it makes the sensor think there is knock when it does not, at 6,000rpm the PCM turns off the sensor and the timing that it pulled gets dumped back in, you can see it in dyno's:
http://memimage.cardomain.net/member...152_9_full.gif
Here is that same run as above(the red one/CWQ3) vs NGP0 and no knock sensor:
http://www.altecxp.net/host/NGP0.bmp

The jump at 6100rpm is the timing being added back in. If the car does not knock after 6000rpm, it will not knock before 6k rpm and is safe to disable, how ever this is only recomended on cars that do NOT have raised compression or forced induction. 89 or 91+ oct may be required.
------------------------------------------------------------------------------------------------------------

Transmissions - Problem

Manual(mtx) - Weak differential(fix: dont do burn outs, invest in a LSD or a Phantom Grip), Syncros and Shift Forks are easy to break with poor driving(fix: dont drive like a dick)

Automatic(atx): Weak Differential, valve body, heat(fix: Install a tranny cooler, dont drive it like a race car, invest in a level10 kit(only suggested if modding for performance))

[zx2guy]

looks good so far there altec. could you add in a few things, these just came off the top of my head

valve clearances
cam lift, duration, and offset
good aem sites , bad ones
typical problem areas (like the auto tranny, and what is indicitive of failure)
any recalls.

you dont gotta add them in, i just figured that covering a topic as vast as the zx2 one cannot possibly cover everything

[AltecZX2]

Originally Posted by zx2guy

looks good so far there altec. could you add in a few things, these just came off the top of my head

valve clearances
cam lift, duration, and offset
good aem sites , bad ones
typical problem areas (like the auto tranny, and what is indicitive of failure)
any recalls.

you dont gotta add them in, i just figured that covering a topic as vast as the zx2 one cannot possibly cover everything

good ideas, I'll see what i can gather up.

[zx2guy]

oooo trans cooler.... i havnt thought about one..... that might be good.
where could i find a good one?
shift kits?

i also thought about guages.... are there guage sets.... or information modules (like the plug ins that bully dog has....) that shows exhaust temps, 0to60 times.... and other guages. this is mostly because i hate dummy guages.... and i like to actually see as much motor information i can.

any you know about or like?

[AltecZX2]

b&M cooler

shift kit = cheap....get a chip

also a chip should give u temps if you log the pcm while driving.



wtf u gonna use exst. temp for?


those are more mods, they really have nothing to do with mainenance, specs, or common problems

[AltecZX2]

Why is this not a sticky?

[pre98zetec]

Originally Posted by zx2guy

oooo trans cooler.... i havnt thought about one..... that might be good.
where could i find a good one?
shift kits?

i also thought about guages.... are there guage sets.... or information modules (like the plug ins that bully dog has....) that shows exhaust temps, 0to60 times.... and other guages. this is mostly because i hate dummy guages.... and i like to actually see as much motor information i can.

any you know about or like?

i know how to install a oil pressure guage.

1. Take off your coil pack, not just remove wire.. take it ALL the way off.

2. You will see a small hole in the coil pack mount (if you don't remove the mount)

3. There will be a star shaped plug in the head, remove it (you will lose a little oil, but not much).

4. Get a mechanical oil pressur eguage and hook the hose up in the head.

5. If you don't have a hole in the coil pack mount you have two options.
1. drill a hole in the mount.
2. get a T fitting and some spacers and move the coil pack out a inch or so to clear the T.

6. reassemble.. get the firing order right ..
4321.....43
...........12

7. find a place to mount it, make sure fittings are tight when you do.

8.. enjoy..

[zx2guy]

sweet thats pretty cool..

[justhere02]

Do you think you could tell me where to find the coolant temp sensor on my '02 ZX2? I'm at a loss here and need to find it so I can try to change it out. I've looked everywhere. I got the replacement part off www.autozone.com under coolant temperature sensor for my yr and model, but now I'm wondering if they sent me the wrong part?! I'm in the UK so I can't just roll down to the local parts store...they don't even make the car here...so I'm kind of stuck. I'm trying to ship my car off back to the states this week but it has to be running for me to be able to do that. PLEASE, can you help me????? It would be GREATLY appreciated!!

[brandone1987]

i was wondering if you could explain the knock sensor part on you thread to me a little bit better im not exactly understanding what you mean by engine knock and dumping timing back in.

[AltecZX2]

Originally Posted by brandone1987

i was wondering if you could explain the knock sensor part on you thread to me a little bit better im not exactly understanding what you mean by engine knock and dumping timing back in.

The knock sensor(KS) on the Zetec is over sensitive to vibration and think that its hearing detonation(or knock). The sensor is disabled at 6,000rpm by default in the computer, that is why you see a power jump at 6,000rpm in a ZX2 dyno even though the power is dropping off, the timing it had pulled is being put back into the car and the power comes back. When you unplug the KS the timing will be kept and you make more power in the power band, you can usually feel it to, the car will be quicker and more responsive, even idle better.

The normal ZX2 PCM is running about 11* max timing, the S/R PCM's are running 13-16* timing. I'm running 34* timing and have no detonation(93 oct).

[NITROJC]

Originally Posted by AltecZX2

Powertrain
Drivetrain: Front Wheel Drive
Engine: 2.0L Zetec Inline-4 iron block & aluminum head Variable Cam Timing(VCT)
Valvetrain: 4 valves per cylinder DOHC (DOHC 16V)
Bore/stroke (in/mm): 3.34x3.46 / 84.8x88.00
Displacement: 121 cu in
Compression ratio: 9.6:1
Horsepower: 130@5750
Torque (lb-ft): 127@4250
Oil capacity (quarts): 4.5
Fuel tank (gallons): 12.7

Transmission - G5M (Mazda designed)
5 Speed MTX Gear Ratios
1st - 3.307:1
2nd - 1.833:1
3rd - 1.310:1
4th - 1.030:1
5th - 0.795:1
Final Drive - 4.10:1
Reverse - 3.166:1

4 Speed ATX Gear Ratios
1st - 2.80:1
2nd - 1.54:1
3rd - 1.00:1
4th - 0.70:1
Final Drive - 3.74:1
Reverse - 2.330:1

Dimensions
Wheelbase: 98.4
Overall Length: 175.2
Overall Width: 67.4
Overall Height: 52.3
Base Curb Weight (lbs) 2478
Towing Capacity Max (lbs): 1000
------------------------------------------------------------------------------------------------------------
Powertrain Control Module (PCM, ECU)
98-99 ZX2’s have a four (4) wire MAF and can only correctly use a 98-99 ZX2 PCM
(there is a wire hack to allow 99.5-03 PCM usage)
99.5-03 ZX2’s use a six (6) wire MAF and can only use 99.5-03 PCM correctly

S/R and Ford Racing PCM’s
NGP0 (1999 S/R, FR) calibration 155MPH speed limiter, added timing, refined fuel rated 10% power increase (Cali emissions)
CWQ3 (2000 S/R) minor fuel curve tweak, small addition to timing 160MPH speed limiter (45 state legal)
XHG3 (2000 S/R) same as NGP0 with less timing (same timing as CWQ3 (Cali emissions)

As of 2001 Ford started adding fuel and taking away timing from the cars via the PCM calibration, in 2003 that cars are no longer making the power they were originally rated at in 1998. 2003 codes are to be avoided at all costs, and it is recommended that if you have a 2003 ZX2 that you will get better mileage and a small power increase from moving to a 99.5-2001 PCM. If you have an original PCM in your car from 98-2001 DO NOT LET FORD UPDATE YOUR PCM.

If needed I can show an image of a CWQ3 dyno vs a GRS0 (CWQ3’s 2003 ‘updated’ counterpart) and there is a 19whp/14wtq loss.
------------------------------------------------------------------------------------------------------------
S/R Package
143hp/140tq

2000 S/R
Only 2000 produced
Iceman intake
Leather shift boot
B&M Short throw shifter
Centerforce Performance Clutch
Retuned PCM
Tokico Struts
Energy Suspension Bushings
Eibach Lowering Spring
Borla exhaust
S/R wheels: 205/55ZR15 Goodyear Eagle
Rear disc brakes
Silver gauge surround
150 MPH speedometer
Ford Blue valve cover
Available in zinc yellow, red and black

1999 S/R
Only 106 produced
Same as above either the following changes
Roush intake
Black valve cover
Escort GT wheels
Zinc yellow only
------------------------------------------------------------------------------------------------------------
Variable Cam Timing (VCT)

The exhaust cam on the ZX2makes use of a VCT system that will retard the cam up to 6* to help lower emissions as the ZX2 does not have an EGR system, as a side effect the torque is not as great as the Focus Zetec but the ZX2 has a longer power band, its also runs more aggressive cams.
------------------------------------------------------------------------------------------------------------
Parts Upgrades

The following parts can be used form other cars on the ZX2 as an upgrade.
Rear disc breaks from: Escort GT, 98+ Tracer, Mid 90’ Protégé, possibly and MX3
Rear sway bar from: Escort GT (19mm), 2nd gen Escort wagon (21mm)
Strut bars for an MX3 also fit the ZX2, and a few MX3, and Protégé suspension parts will also work.

Aside from the head, the ZX2 and Focus Zetec motors are the same. Intakes, and exhaust cams for a Focus will NOT work on a ZX2, a header will work with some fabrication. ZX2 stock cams are more aggressive than Focus cams.
------------------------------------------------------------------------------------------------------------

Knock Sensor
Unplugging the knock sensor can cause your car to run more timing and produce more power, the gain depends on the calibration of your stock PCM....this does no/little good for those running NGP0.

The vibration from the head is enough that it makes the sensor think there is knock when it does not, at 6,000rpm the PCM turns off the sensor and the timing that it pulled gets dumped back in, you can see it in dyno's:
http://memimage.cardomain.net/member...152_9_full.gif
Here is that same run as above(the red one/CWQ3) vs NGP0 and no knock sensor:
http://www.altecxp.net/host/NGP0.bmp

The jump at 6100rpm is the timing being added back in. If the car does not knock after 6000rpm, it will not knock before 6k rpm and is safe to disable, how ever this is only recomended on cars that do NOT have raised compression or forced induction. 89 or 91+ oct may be required.
------------------------------------------------------------------------------------------------------------

Transmissions - Problem

Manual(mtx) - Weak differential(fix: dont do burn outs, invest in a LSD or a Phantom Grip), Syncros and Shift Forks are easy to break with poor driving(fix: dont drive like a dick)

Automatic(atx): Weak Differential, valve body, heat(fix: Install a tranny cooler, dont drive it like a race car, invest in a level10 kit(only suggested if modding for performance))

HELLO FOLKS, I have the 1999 ZX2 ford escort 2.0l. I don't know anything about these new componets VCT, NGPO, ETC. The other day the car was running fine as usual. I turn off the engine. Minutes later restarted it with No problem, went to back up, and the accelerator felt different. I went to pull out into traffic, and the engine felt as if it was double firing with little to No power. In order to accelerate at a slow rate, I had to put the petal to the metal, just to get home. Yes, The car stunk badly after turning it off. I HAVEN'T A GLUE AS TO WHAT THE PROBLEM IS !! This has never happened before .... I have 70,700 miles on it.
PLEASE ADVISE, as to what the possible, or problem is.
Thank-You All, Nitrojc.