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-   -   My SVT header swap (http://www.focusfanatics.com/forum/showthread.php?t=316481)

homelessmonkey 05-14-2013 12:09 AM

My SVT header swap
 
Hey everyone, so this past weekend I finally ended up doing my SVT swap by myself. Let’s just say I think it would’ve been easier with someone else but oh well I got the job done :P just took me the whole day 9am-midnight with some breaks along the way. Anyways I just wanted to share with everyone my swap experience so I will try and be the most detailed I can be feel free to ask question or let me know if I should’ve done something different. Also I tried to take the most pictures I could but I did not want to get my camera too dirty. Okay let’s get this thread started.


First off here’s a list of what I used :
1.Used SVT header, I wanted to stay legal so I got an shop to wield in the egr connector( ford part #F1AZ-9F485-A)
Before
[IMG]http://i1309.photobucket.com/albums/...psa515dd55.jpg[/IMG]

After abit of sanding
[IMG]http://i1309.photobucket.com/albums/...ps688d91c5.jpg[/IMG]
[IMG]
[/IMG]

2 tubes wrapped
[IMG]http://i1309.photobucket.com/albums/...ps04691505.jpg[/IMG]
[IMG]http://i1309.photobucket.com/albums/...psef244ef9.jpg[/IMG]

All wrapped up but had to unwrap 2 tubes cause i forget to get the bung welded in [facepalm]
http://i1309.photobucket.com/albums/...psb8ff9db6.jpg

With the bung welded in
[IMG]http://i1309.photobucket.com/albums/...ps9eda7bd1.jpg[/IMG]

2.Used SVT cat, the 2 02 sensors I got with them were good all I did was make 2 extentions from just yard ones.

Before
[IMG]http://i1309.photobucket.com/albums/...ps383f701e.jpg[/IMG]

After
[IMG]http://i1309.photobucket.com/albums/...psb85e54f5.jpg[/IMG]

3.Used Svt flex, i just sanded it and sprayed it with black vht
[IMG]http://i1309.photobucket.com/albums/...ps7d3bc8c6.jpg[/IMG]

4. 2 02 extention wires, 2 02 sensors for the cat
[IMG]http://i1309.photobucket.com/albums/...ps8de715d1.jpg[/IMG]

5.Used egr tree with valve from junk yard 10$
[IMG]http://i1309.photobucket.com/albums/...ps78df5863.jpg[/IMG]

6.New gaskets for head to header, header to cat, cat to flex, flex to straight
[IMG]http://i1309.photobucket.com/albums/...psb29df67b.jpg[/IMG]

7.New nuts and bolts
[IMG]http://i1309.photobucket.com/albums/...ps532df80f.jpg[/IMG]

8.New SVT[IMG]http://i1309.photobucket.com/albums/...ps46277d6f.jpg[/IMG] oil dipstick and tube


First off here is what the engine bay looked like
[IMG]http://i1309.photobucket.com/albums/...ps27957f57.jpg[/IMG]

[IMG]http://i1309.photobucket.com/albums/...ps51e4376e.jpg[/IMG]

[IMG]http://i1309.photobucket.com/albums/...ps35e04372.jpg[/IMG]

[IMG]http://i1309.photobucket.com/albums/...ps7aba914c.jpg[/IMG]

http://i1309.photobucket.com/albums/...ps7e0771af.jpg

So i started from with the bolts from the straight pipe to flex, then I could not undo the bolts from the flex to cat it was nice and rusted together so i undid the hanger bolts then the cat to header bolts and then the header bolts.
Here is when i ran into my first problem there bolt from the egr tube that connects to the bun was rusted on there and would not wanto move at all. I went at it with a torch and made it glowing red and still no movement. So i said screw it and i just cut the pipe since I already had one.

http://i1309.photobucket.com/albums/...psab8ad7e3.jpg
http://i1309.photobucket.com/albums/...ps1a692d9d.jpg
http://i1309.photobucket.com/albums/...psaf61e53e.jpg
http://i1309.photobucket.com/albums/...ps174dc77d.jpg
Inside of old cat 142km not to bad
http://i1309.photobucket.com/albums/...psdbc59367.jpg
Here is with it lightly fitted on, its just sitting on the studs ATM
http://i1309.photobucket.com/albums/...ps115e6838.jpg

Ps line way too close for it to run safe.
[IMG]http://i1309.photobucket.com/albums/...ps7c9bf832.jpg[/IMG]

http://i1309.photobucket.com/albums/...ps5b99f1f8.jpg
will get back to bending it later.
Here what it looked like from under.
http://i1309.photobucket.com/albums/...ps5b99f1f8.jpg
http://i1309.photobucket.com/albums/...ps3fbfef56.jpg

Attached the SVT cat to header.
http://i1309.photobucket.com/albums/...psf44e0252.jpg

http://i1309.photobucket.com/albums/...ps0cf6ce19.jpg

http://i1309.photobucket.com/albums/...ps129d7a93.jpg

And then here is where I encountered my other problem[?|]
This was me not paying attention to what I was doing. First off the SVT flex will not line up properly without having the holes slotted on it. Well i was dumd and slotted the wrong side so when i was trying to put it on it did not want too line up I realized soon after and was like well that was a waste of time. So started drilling the right side of the flex which is the curved part not the straight side!! I ended up only needing to slot one hole to make it line up.
http://i1309.photobucket.com/albums/...psb99aad86.jpg
http://i1309.photobucket.com/albums/...ps5abdeef3.jpg
http://i1309.photobucket.com/albums/...ps85b66fd4.jpg
http://i1309.photobucket.com/albums/...psb396f7d9.jpg
http://i1309.photobucket.com/albums/...ps0a0c5e63.jpg

An hour later. Finally fitted the flex on
http://i1309.photobucket.com/albums/...ps46a46060.jpg
http://i1309.photobucket.com/albums/...ps75db2bc6.jpg
http://i1309.photobucket.com/albums/...psa5348293.jpg

Fitted the rear 02 extension on
http://i1309.photobucket.com/albums/...ps67d08c8f.jpg
Then front
http://i1309.photobucket.com/albums/...ps23920ae9.jpg

So everything is on except the egr tube i had to bend it slightly to be able to make it fit but that was pretty easy thanks to the torch.
Got it fitted on there nice.
http://i1309.photobucket.com/albums/...psd142bc75.jpg

I also bend the ps line with a heat gun i did not want too take the chance with the torch since there was a coolant tube next too it. I only bend it out of the way of the header towards the front of the car so it is not touching the header but its touching the coolant tube witch i think should be okay.
did not take anypics of this but here is what it looks like after.
http://i1309.photobucket.com/albums/...psd51f7e01.jpg

And that's, when i started up the car I got 3 codes thrown at me if anyone knows if this is normal or what I should do with these codes please let me know. P0113,P0102,P0340

Here is also 2 videos the first one is with the everything. The second is with the SVT swap with zx3 magnaflow exhaust with no resonator. For a while I was running just a zx3 magnaflow with stock header,cat,flex forget to take video before but I find it sounds smoother after the swap since the piping is closer to the same size let me know which you like better.

Thanks for reading everyone, i hope this will help anyone that is looking to do an SVT swap on there Zetec.

http://i1309.photobucket.com/albums/...ps9914ca16.mp4
http://s1309.photobucket.com/user/ho...7643e.mp4.html

katiekay 05-14-2013 09:41 PM

Nice! What size bolts did you use?

Tundrafoci 05-15-2013 03:09 AM

Wow. This is awesome I'm just about to start this project! thanks alot rep to you!

CotyM 05-15-2013 11:49 AM

Awesome, can't wait to start doing mine, collecting parts slowly but surely...

Anyway, thanks this gave me some incite on the project, and did I see your car blow a smoke ring??? +1 rep for smokering. [grinking]

marcanjelo7 05-15-2013 01:08 PM

hey just curious, how much they charge you to weld in the bung?

drunkyoda 05-15-2013 01:09 PM

that took you a long time... it only took me like a couple hours..

ZXthrizzle05 05-15-2013 01:26 PM

same, I also ditched the egr thou. welded it shut

zetecDon 05-15-2013 03:19 PM

I had mine done in just a couple of hours as well. I also went the route of getting an SVT high pressure line so I didn't have to fool with bending the stock line.

blackfocus2k4 05-15-2013 04:57 PM

i did this with my JRSC install i had my headers ceramic coated though. I bought the CFM relocation hose for the power steering line worked pretty good just had to make it a little shorter. This with the supercharger brings the car to life!

homelessmonkey 05-15-2013 07:22 PM

Quote:

Originally Posted by pyroinsa (Post 4725404)
Nice! What size bolts did you use?

Sorry i cant remember what size i used wrote down everything else but not the bolt sizes.
Quote:

Originally Posted by Tundrafoci (Post 4725688)
Wow. This is awesome I'm just about to start this project! thanks alot rep to you!

np glad to help out
Quote:

Originally Posted by CotyM (Post 4726065)
Awesome, can't wait to start doing mine, collecting parts slowly but surely...
Anyway, thanks this gave me some incite on the project, and did I see your car blow a smoke ring??? +1 rep for smokering. [grinking]

lol maybe :P, which video ?
Quote:

Originally Posted by marcanjelo7 (Post 4726177)
hey just curious, how much they charge you to weld in the bung?

The shop i went to charged me 20$ canadian so im guessing 15 us?
Quote:

Originally Posted by drunkyoda (Post 4726180)
that took you a long time... it only took me like a couple hours..

Yeah i had alot of trouble getting that egr nut off i tried for at lest and hour i couldn't get it so i just cut it. and i was in no rush i just took my time and had alot of smoke breaks if you know what i mean :P


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