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Old 06-16-2008, 09:09 AM   #1
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2000 SPI to 2004 Zetec Swap

Hello, I have just gotten my car running after swapping from a 2000 SPI to a 2004 Zetec. I swapped all the required elements and I still have to correct a relatively large exhaust leak between the manifold and my downpipe but I am having a number of problems.

1. rough idle (especially when cold)
- The idle also tends to wander a bit

2. I am pulling a code for a lean condition and I can't find any obvious vacumn leaks.

I am hoping that both of these conditions are likely due to the O2 sensor not getting enough exhaust at low RPMs to properly regulate the fuel/air mixture. Is this likely?

I have also removed the EGR system and plugged the intake with a bolt and JB Weld were the EGR connects. I did also change the speed control module. with a new one for the Zetec.



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Old 06-16-2008, 02:58 PM   #2
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have you had a tune done to eliminate the EGR system. If not I would put money that is where your problem lies since you plugged it off. When I did my swap I changed over the EGR System and left it hooked up. When I completed mine I didn't have any idle issues.

As for the lean code, do you still have the CAT in place? Did you install a SRI/CAI?
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Old 06-16-2008, 03:52 PM   #3
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I didn't bother with a tune, my understanding is it will just throw a code (which I am getting) but not actually cause any problems. The CAT is not present, nor is the second O2 sensor (I am also getting the code for the lack of this sensor of course). I put a K&N filter on the end of the MAF and intake tube for now but will likely install a CAI in the near future.

I will be installing an aftermarket CAT and second O2 sensor in the next couple of weeks My buddy and I just jerry rigged a quick exhaust to get the car back up to Edmonton.
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Old 06-17-2008, 07:45 AM   #4
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Those would be your reasons for rough idle, especially if there is not even a second O2 sensor. That is what helps regulate your fuel, and probably making your car run lean.

I bought an aftermarket exhaust header and Flex and used an O2 extender to pull the secon O2 sensor out of the direct path. Your could do the same if you just wanted to run Hollowd CAT for visual inspection, then use the O2 Extender to fix the CEL




And I also just a filter on the MAF and Intake tube.

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Old 06-17-2008, 09:07 AM   #5
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I am getting conflicting information now about this 2nd O2 sensor. Everything else I have heard is that the only thing the 2nd O2 does is check to make sure the CAT is there. This is why the O2 cheater (adding a low pass filter) on the O2 output works. The filter takes the raw output of the O2 sensor and smooths it out, removing the cross-over points. The computer then compares the signal from the 1st O2 sensor to the second and if the signals are too similar it throws the code that the CAT is not functioning.

Alberta doesn't really check for emmissions equipment at all so I wouldn't bother with the hollowing out business. I do think it is important to have a CAT in order to decrease the amount of noxious gases emitted. And there are CATs out there that don't drop performance much at all.

I do eventually want to put a CAT back in (and the second O2 as well); what I was thinking was a shorty header with a high flow cat right below in the stock location (stock location on the SPI at least, not sure about the Zetec). Might have to do this sooner rather than later.
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Old 06-22-2008, 05:17 PM   #6
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My buddy and I corrected the exhaust leak today and both the problems of the rough idle and the lean code have been corrected. That and it doesn't sound like a rock truck anymore! Hopefully the fuel economy gets a little more reasonable as well but I might need to reconnect the EGR for that to happen.
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Old 06-29-2008, 09:10 AM   #7
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What did you have to change for this swap? The wife has an spi sedan and I am curious what all is involved.
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Old 06-29-2008, 10:32 PM   #8
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BluefocusSVT04:

The major parts list is as follows:

Zetec Engine
MTX75 Transaxle
Axles
Passenger side axle bearing/bracket
Alternator
Powersteering pump
Powersteering hydraulic pressure line
AC Compressor (maybe, depending if you break the lines or not)
ECU
Main wiring harness
shifter/shift cables
cruise controller
cruise cable
throttle cable
clutch hydrualic line
throw-out bearing
clutch disc
pressure plate
flywheel
Exhaust (either custom or the downpipe and cat from a zetec)
Intake hose (either stock or aftermarket intake)

There are probably a few things I am missing as well. I also had to change the crank position sensor on my Zetec engine because it came from an automatic It would obviously be easier to get one from a standard but I had trouble sourcing one where I live.

I went with a custom exhaust (obviously) and I love the sound. This is not an easy swap by any stretch of the imagination. I know a few people on here have done it and it is easiest if you have a wrecked focus to use as a donor car.
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Old 06-29-2008, 10:49 PM   #9
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thanks bro
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Old 07-23-2008, 02:07 PM   #10
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wireing harnes from the motor back to the gas tank
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