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Old 05-14-2013, 01:09 AM   #1
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What I Drive: 2003 black zx3

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Thumbs up 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)

After abit of sanding

2 tubes wrapped

All wrapped up but had to unwrap 2 tubes cause i forget to get the bung welded in

With the bung welded in

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.



3.Used Svt flex, i just sanded it and sprayed it with black vht

4. 2 02 extention wires, 2 02 sensors for the cat

5.Used egr tree with valve from junk yard 10$

6.New gaskets for head to header, header to cat, cat to flex, flex to straight

7.New nuts and bolts

8.New SVT[IMG][/IMG] oil dipstick and tube

First off here is what the engine bay looked like




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.

Inside of old cat 142km not to bad

Here is with it lightly fitted on, its just sitting on the studs ATM

Ps line way too close for it to run safe.

will get back to bending it later.
Here what it looked like from under.

Attached the SVT cat to header.

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.

An hour later. Finally fitted the flex on

Fitted the rear 02 extension on

Then front

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.

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.

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.

Last edited by homelessmonkey; 05-14-2013 at 08:27 AM.
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