Ford Zetec E Tuning Guide

Ford Zetec E Engine

The name Zetec is pretty confusing because it’s now used by Ford as a badge on the back to describe a level of trim. On top of this, there’s a smaller capacity Zetec - described elsewhere - plus, late Zetecs were made to look like the latest Duratecs.
Early, ‘Silver Top’ engines (with an aluminium cam cover) were fitted to Escorts from 1991 onwards, late Fiesta Mk3s and then the Mondeo. These early units were known as Zeta (only becoming Zetec in 1993). The unit evolved into the Black Top unit (with a plastic cam cover) with the Escort phased out and Focus introduction. These later engines have longer rods and lower piston crowns, mechanical rather than hydraulic lifters plus the distinctive black cam cover.

Initially there were 90, 105 and 115bhp 1800cc Escort versions, with 115 and 130bhp 2 litre Mondeo units too. There were also 130bhp RS1800 Fiesta/XR3i variations with revised cams and re-mapped ECU’s. The hottest n/a version was the ST170 with solid lifters, steel rods, waisted valves and variable valve timing (VVT). The motor went on to power the Focus RS but in turbocharged form. Both the ST and RS engines were confusingly re-badged as a Duratec.

As far as tuning goes, it’s simple to bring an 1800 up to RS1800 spec with Ford cams or Kent FZ1802 cams - you would need a 130bhp ECU though, or aftermarket re-mapping. A power boost valve will help eliminate the flat spot between 3,300-3,500rpm.
You can actually use the standard injection combined with a new Weber Alpha kit that works with the OE inlet manifold. Fitments are for the silver top 1800s, and both silver and black top 2.0 engines. Power achieved is, approx 150bhp for a 1.8 130PS and 160bhp for the 2.0. However, these are really the limit of the standard induction and further increases are not possible, unlike their other kits. It has to be said that although these kits have been developed for the kit car market, we do not see any reason why they can’t be fitted to a FWD Zetec engined car. Webcon cannot confirm fitment but like us believe it should work. If you want to go beyond the range of the standard induction though, we can supply a Weber Alpha kit, which replaces the system altogether and is incredibly comprehensive - all is there for you to bolt it straight on, including manifold, linkage, even air filters. On an 1800 130PS engine, you should see 155bhp and 165bhp on a 2 litre.
Either of these two systems will provide enough fuelling for plenty of future modifications. Fit one of our stage 1 heads plus a pair of Kent FZ2002 cams and you should see power around 185bhp. If you want to go beyond this ‘Fast Road’ stage then you’ll need our Stage 2 heads which feature larger inlet valves.
The Kent FZ2003 cams will give you between 200-240bhp depending on stage of head, coupled with 48mm throttle bodies. However, at this stage, you’ll need larger followers machined and installed, otherwise the cam lobe won’t be completely ‘seen’ by the follower. We’d also recommend a capacity increase to 2.1 litres, with an 86mm bore plus our Accralite pistons. The standard crank is very strong but around these levels we’d encourage the switch to steel along with our Farndon H-section rods.

The Zetec E is also a popular swap into a classic Ford usually requiring turning round to rear wheel drive format. We can supply all the parts you need to do this including the water rail manifold, which re-locates the thermostat housing, thus providing bulkhead clearance. In addition, we have access to engine mounts for Mk1 and 2 Escorts, correct orientation sumps, exhausts and everything you need to give your classic, modern 16 valve power.

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  1. Airtec intercooler kit: Ford Focus RS 2.0 stage 1 natural silver finish ATINT33
    £655.90 (inc VAT)
    (ex VAT) £546.58

    Part Number: ATINT33

    A huge Airtec front mount intercooler kit with 70mm core. Po.... Learn More
    Stock Lead Time Typically 3-4 weeks
  2. Airtec intercooler kit: Ford Focus RS 2.0 stage 1 black ATINT33BK
    £655.90 (inc VAT)
    (ex VAT) £546.58

    Part Number: ATINT33BK

    A huge Airtec front mount intercooler kit with 70mm core. Pr.... Learn More
    Stock Lead Time Typically 3-4 weeks
  3. Samco blue radiator water coolant silicone hose set (2 hoses): Ford Focus Mk1 ST170 TCS-541\C
    £118.90 (inc VAT)
    (ex VAT) £99.08

    Part Number: TCS-541/C

    Hand made from premium quality silicone rubber, SamcoSport h.... Learn More
    Available From Stock
  4. Samco blue water coolant silicone hose set (8 hoses): Ford Focus Mk1 ST170 TCS-541\ANC
    £245.50 (inc VAT)
    (ex VAT) £204.58

    Part Number: TCS-541/ANC

    Hand made from premium quality silicone rubber, SamcoSport h.... Learn More
    Available From Stock
  5. Motorcraft radiator cap, screw thread plastic type ERS43
    £19.75 (inc VAT)
    (ex VAT) £16.46

    Part Number: ERS43

    Plastic screw-on type header tank cap. Fits most Ford late t.... Learn More
    Available From Stock
  6. Samco blue heater water coolant silicone hose set (2 hoses): Ford Focus RS 2.0 Mk1 TCS-238\H
    £82.90 (inc VAT)
    (ex VAT) £69.08

    Part Number: TCS-238/H

    Hand made from premium quality silicone rubber, SamcoSport h.... Learn More
    Stock Lead Time Typically 8-12 weeks
  7. Samco blue silicone turbo boost hose set (2 hoses): Ford Focus RS 2.0 Mk1 TCS-238
    £117.50 (inc VAT)
    (ex VAT) £97.92

    Part Number: TCS-238

    Hand made from premium quality silicone rubber, SamcoSport h.... Learn More
    Stock Lead Time Typically 4-5 weeks
  8. Airtec intercooler kit: Ford Focus Mk1 RS 2.0 stage 2 natural silver finish ATINT11
    £804.50 (inc VAT)
    (ex VAT) £670.42

    Part Number: ATINT11

    Huge Airtec Focus RS Front mount Intercooler kit with 100mm .... Learn More
    Stock Lead Time Typically 3-4 weeks
    Free UK Delivery Available
  9. Airtec alloy chargecooler radiator: Ford Focus RS 2.0 black ATRAD7BK
    £264.95 (inc VAT)
    (ex VAT) £220.79

    Part Number: ATRAD7BK

    Finished in pro-series black. Huge 70mm core. No extra modif.... Learn More
    Stock Lead Time Typically 4-5 weeks
  10. Airtec intercooler kit: Ford Focus Mk1 RS 2.0 stage 2 black ATINT11BK
    £804.50 (inc VAT)
    (ex VAT) £670.42

    Part Number: ATINT11BK

    Huge Airtec Focus RS Front mount Intercooler kit with 100mm .... Learn More
    Stock Lead Time Typically 3-4 weeks
    Free UK Delivery Available
  11. Samco blue water coolant silicone hose set (6 hoses): Ford Fiesta Mk3 1.6\1.8 16v Zetec Si\XR2i\RS1800 02\94-12\95 TCS-404\C
    £296.95 (inc VAT)
    (ex VAT) £247.46

    Part Number: TCS-404/C

    Without air conditioning Learn More
    Stock Lead Time Typically 4-5 weeks
  12. Samco blue silicone turbo boost hose set (2 hoses): Ford Focus RS 2.0 Mk1 (with dump valve outlet) TCS-238D
    £124.90 (inc VAT)
    (ex VAT) £104.08

    Part Number: TCS-238D

    Hand made from premium quality silicone rubber, SamcoSport h.... Learn More
    Stock Lead Time Typically 8-12 weeks
  13. Samco blue ancillary water coolant silicone hose set (8 hoses): Ford Focus RS 2.0 Mk1 TCS-238\C-A
    £264.95 (inc VAT)
    (ex VAT) £220.79

    Part Number: TCS-238/C-A

    Hand made from premium quality silicone rubber, SamcoSport h.... Learn More
    Available From Stock
  14. Samco blue water coolant silicone hose set (10 hoses): Ford Focus RS 2.0 Mk1 TCS-238\C
    £331.90 (inc VAT)
    (ex VAT) £276.58

    Part Number: TCS-238/C

    Hand made from premium quality silicone rubber, SamcoSport h.... Learn More
    Available From Stock
  15. Samco blue water coolant silicone hose set (8 hoses): Ford Escort\Orion Mk5\Mk6 1.6\1.8 Zetec (not 130PS) TCS-225\C
    £399.95 (inc VAT)
    (ex VAT) £333.29

    Part Number: TCS-225/C

    Hand made from premium quality silicone rubber, SamcoSport h.... Learn More
    Stock Lead Time Typically 5-6 weeks
  16. Samco blue water coolant silicone hose set (8 hoses): Ford Focus Mk1 1.8\2.0 RHD TCS-198\C
    £335.95 (inc VAT)
    (ex VAT) £279.96

    Part Number: TCS-198/C

    Hand made from premium quality silicone rubber, SamcoSport h.... Learn More
    Stock Lead Time Typically 8-12 weeks
  17. Samco red water coolant silicone hose set (8 hoses): Ford Focus Mk1 1.8 & 2.0 RHD TCS-198\C(RED)
    £335.95 (inc VAT)
    (ex VAT) £279.96

    Part Number: TCS-198/C(RED)

    Hand made from premium quality silicone rubber, SamcoSport h.... Learn More
    Stock Lead Time Typically 8-12 weeks
  18. Radiator cap, screw thread plastic type FC500
    £4.99 (inc VAT)
    (ex VAT) £4.16

    Part Number: FC500

    Available From Stock
  19. Thermostat Ford Zetec E 92deg QTH578K
    £9.50 (inc VAT)
    (ex VAT) £7.92

    Part Number: QTH578K

    Available From Stock
  20. Pro Alloy intercooler kit: Ford Focus RS 2.0 Mk1 PROINT8
    £1,740.00 (inc VAT)
    (ex VAT) £1,450.00

    Part Number: PROINT8

    Essential for tuned engines, this huge RC style front mount .... Learn More
    Stock Lead Time Typically 1-2 weeks
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