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Old 09-12-2009, 08:54 PM   #1
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SPI to Zetec swap with no donor car

I did a bunch of searching and reading to find out what I needed to do a SPI to Zetec swap. I dropped a valve seat in the #4 cylinder and decided to swap instead of fix the SPI. As I was doing the swap there were quite a few parts that I needed that I don't think got explained real well in the threads I have read. I just finished my swap and I wanted to list all the parts that are needed to do this. This is for an automatic transmission.

Engine
Powertrain Control Module
Zetec Engine Harness (all three sections - harness on transmission from the SPI does not have the post catalyst o2 plug or the crank sensor plug)
Motor mount
Motor mount bracket (Zetec mount will not work with SPI bracket)
Exhaust (catalytic converter is different between the two engines)
Power steering pump
Alternator
A/C pump can be used if you bend the lines (kind of scary but you can make it work)
Plastic coolant pipe that runs along the top of the radiator support
Vacuum line for the vapor purge valve
Coolant line from heater to plastic pipe
Coolant line from pipe to thermostat
Lower radiator hose
Intake tube
Throttle cable (SPI cable has different ends)
Hardware for alternator and power steering pump
I was able to use the line from the power steering reservoir to the pump but I think I may have flipped it around.
Your keys and PCM need to be reprogramed


I made a new end for the SPI cable (dealer wants $105)


This is the plastic coolant pipe


Here is the Zetec mount and bracket


You need 8290,8555,8K012,8286,18K359,18472. I used one of the coolant lines from the SPI (the one with the T) to go from the heater to the back side of the thermostat. I bought some 5/8 heater line for the heater to pipe and pipe to thermostat istead of buying the formed hoses.

Hope this helps anybody that is considering this!


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Old 09-13-2009, 09:09 AM   #2
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i am in the process of doing this as well. but i only changed the passengers side harness that goes form the ecu to the engine bay and the under hood engine and tranny harness. i am just about done and i have had the car for 6 days now. my biggest problem has been the exhaust and figuring out wwhat i am gonna do for the ignition.

before anyone asks i have previoulsy done a swap. i have done a auto/zetec to a manual svt swap on my car. the spi to zetec i am doing is on a car i bought for my girlfriend so i had most of the parts from my swap. we picked her up an 01 lx for $400 w/ a blown motor. good deal if you ask me.

Thanks this clarified what exactly i needed to do.
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Old 09-13-2009, 08:14 PM   #3
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How many of you guys/gals reading this have heard of or have had their SPI engine drop a valve seat in # 4? Just curious, but was your dropped seat on the intake? I'd almost bet it was. Just a couple examples that I have first hand knowledge of. The first one is my wife's '00 SE wagon. The car had 140k on it when it did this. We were 150 miles away from home, visiting her mother at Christmas. Left her mom's and drove the car about thirty miles, then stopped at Bestbuy to do some shopping. I guess we were in the store about an hour. Came out, started the car, put it in gear and had a sudden death rattle. I shut it down, but it was already too late. The dropped seat wedged the intake valve open which shattered the piston, which then caused the wrist pin to crack the block. All in about 5 or 10 seconds. That car is currently undergoing a 2.0 Duratech swap which I will document on here very soon. I'm nearly done with the swap.
The second one was my nephew's '00 SE sedan with about 127k on it. It did exactly the same thing, with the same end result and exactly the same broken parts. The two broken engines were virtually identical. The only difference with his was that it sat for a couple hours and he drove it about eight miles after start up before he got the death rattle, but otherwise, everything was the same. He was on more of a budget than me so he swapped a low mileage SPI into the car with the knowledge that it will probably do it again. As far as I'm concerned, you can't tell me that Ford didn't know it had a defect. More like designed in obsolesence... so you'll buy another Ford. I don't think so. Anybody else out there have any opinions on this?
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Old 09-14-2009, 11:02 AM   #4
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Yes it was the #4 intake valve seat at 118,000 miles.
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Old 09-16-2009, 12:41 PM   #5
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Is there much of a difference in acceleration with the Zetec? I have an auto SPI wagon and it's pretty pathetic, especially at highway speed, it makes a lot of noise but the passing power is non existent.
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2.0L SPI, automatic
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Old 09-16-2009, 04:58 PM   #6
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It is a little quicker. You gain 20 hp. The difference is not huge though. I recently put 17s on my car and I noticed it slowed the car down even though the overall diameter of the tires did not change. It is better now with the Zetec.
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