2.0 Zetec turbo
 

I just finished building my homemade turbo on my 99' Mercury Cougar. This set-up is using a Garrett/Turbonetics T-3 .48/.60, Tial external wastegate, 1G Mitsubishi by-pass valve, FMIC and 36 lbs injectors.

Fuel and ignition timing is being controlled by a Greddy E-Manage and MSD DIS-2 programmable ignition controller.

http://www.newcougar.org/forums/atta...1&d=1077346834

Re:2.0 Zetec turbo
 

very nice. How do you like the greddy e-manage? Easy to play with? I'm thinking about getting that unit.

Re:2.0 Zetec turbo
 

Thanks, I like the E-Manage.......it has many great features such as fuel injector calibration (recalibrate the MAF voltages), programmable 16X16 fuel maps, programmable injector duty cycle, support for two additional injectors, additional MAP based fuel maps and anti-stall .........etc. Once I figured out how to wire it up to the Ford EEC-V ECU it was a pleasure to work with. Also, the data logging is a great feature.

You'll need to get the support software/cable and use a laptop to take full advantange of it's capabilities though.

Re:2.0 Zetec turbo
 

So you can do all the programing your self or did you go to a shop?How much did you pay for it?

Re:2.0 Zetec turbo
 

sounds great. I know someone that is selling thier E-manage. He has the injector harness, ignition harness, the support software and cable. Does $450 sound reasonable?

Re:2.0 Zetec turbo
 

Yes, I do all the programming myself. But in order to see what's going on with the engine, I also use an Autotap OBDII monitor/reader and a LM-1 WB meter. You could always have a shop tune it for you, but it's not hard to do by yourself.

I picked up my E-Manage with ignition harness, support software and cable for $325.00. It was sold as used but it was never installed (I think I got a great deal......... ;D)

$450.00 for the main unit, ignition harness, sub injector harness, support software and cable is reasonable. That's about what that would cost new (less shipping cost). If what you're getting is new, then I'd say that's not a bad price.

Re:2.0 Zetec turbo
 

it is actually used. A guy from tundrasolutions is trying to sell it.

Re:2.0 Zetec turbo
 

So how far can you adjust the fuel with the blue box? Ive done the AFC hack and I know I can take it to -40% if I wanted and from what I understand you can only do it to like -15-20% with the box. Is this right or does the software package really do that much for it?

Re:2.0 Zetec turbo
 

The blue box and the e-Manage are 2 diferent things.

Re:2.0 Zetec turbo
 

Thanks for the info. I guess I was always under the misconception that they were one in the same. Well I know how the the blue box works and I read about the emanage. Does the emanage do all the things it says it can? Seems to me like its an advanced safc without the display. I mean its still a piggyback so it still relies on the factory ecu and sensors so how does it trick the ecu to not see boost. Im guessing the same way as the afc (manipulating map voltage), but does it control the injecors in relation to boost or does everything have to be set in percentages like the AFC? This isnt a thread jack I'm just curious. Car looks nice by the way too.

Re:2.0 Zetec turbo
 

Turbo system looks great !! But good luck with the zetec crap... My 2001 focus has broken 3 trannies, and my girl friend drives it.... My honda on the other hand has never broken as much as a starter...

I hate to see good HMTs happen to bad cars... haha...

I saw a magizine do a fully built head, aftermarket intake manifold, F-max turbo kit ( nice BTW ), injectors, MAF, stane alone FMS, dyno tuned, and with race gas it made like 302whp....

I am reminded daily that my $360 a month on my ford is/was a waste of money... Glad I got the 5 year 75K mile warrenty.. Too bad the engine is "lazy", the interoir is pretty good IMO, and I like the styling of the exteroir too, despite the "macco" like factroy paint...

The merc. is a lot sportier, but its the same "....." drive train.

Noless, sweet set-up, and it looks nice and clean man, if you have anymore pics e-mail them to me bleveret@tampabay.rr.com I have so "focus" friends that refuse to leave the focus for a "ricer" hehe, even though ny "ricer" doesn't bother to leave them... They talk about HMTs, but end up buying graffics and body kits while getting smoked by stock hondas...

Re:2.0 Zetec turbo
 

The E-Manage is pretty versatile. It has the ability to clamp the MAF or MAP voltage once the airflow exceeds the MAF or MAP's sensor abilities. Once the voltage is clamped, the fuel maps are controlled by a second MAP sensor that bases the fuel maps off of boost pressure.

The MTX 75 manual transmission is not that bad. I would say it's weak point is the diffrential. Besides the Focus, that transmission is used on the Cougar, Contour and mondeo....on both the 2.0 Zetec and the V6 2.5 duratec. These transmissions should be able to handle 250 whp without any modifications.

Hmmmm, broke 3 trannys?.......what kind of HP is your Focus pushing? If it's just the stock 125 hp, I'd say you must have some really bad luck and just got some bad transmissions.

Re:2.0 Zetec turbo
 

my friend has the same luck with Saturn transmissions, he went through 3 trannies in 25k miles... thats sad

Re:2.0 Zetec turbo
 

I have the auto focus, haha. Its insanly slow !!! Ran 18.4 at the track one night !!! My 89' dx hunchback ran 18.2 the same night bone stock with 155K miles, hehe.

Got anytimes yet ? How much boost ? Is the merc any faster/lighter than the foci in factory forum ??

Re:2.0 Zetec turbo
 

My friend went through 2 tranny's in his dodge stratus with 42,xxx miles and he doesnt even race it or drive stupid, He said when we went do the tranny shop, all there was in there was newer chryslters, Makes ya think dont it

Re:2.0 Zetec turbo
 

hahaha man i remember last time i was at the track with my auto accord and i started to lose the transmission and itd slip soo bad itd hit the rev limiter in every gear, and i kept going up against a kid in a focus 3x and never lost even though the tranny was burnt... It wouldnt even shift out of 1st after that.

Re:2.0 Zetec turbo
 

Haha....I also have a 2000 Focus, 2.0 Zetec w/ an auto trans (it's actually my wife's car).....and it's a real dog....haha! Not bad though........over 82k and no major problems with it. I even offered to put together a turbo for it....but she'd rather get a new car.......... :o

I haven't run the Cougar for times yet. I'm running 7 psi boost and I estimate that it's putting out just under 200 whp (ass dyno). The Focus is lighter 2610 lbs. compared to 2930 lbs. for the Cougar.....but the Cougar has much better road handling traits.

Re:2.0 Zetec turbo
 

Nice!!! Another Zetec checking in, 'cept mines in a ZX2 (ya, it's an escort).

Where'd you find that manifold? My set-ups not done yet, but I'm ghetto rigging a focus mani for mine.

I'm curious, have you heard about SCT for fuel management? I'm going to be going with their flasher version here in about a month (it ain't cheap, but it basically gives you full control over the EEC).

Re:2.0 Zetec turbo
 

Hey, it's nice to see another Zetec in here. I was begining to think I was the only one.... ;D

I got my manifold from JGS Precision. It was an unfinished log manifold and I welded up the T-3 flange, wastegate pipe/flange and ported it out.
They also sell Zetec exhaust flanges if you want to build a weld el manifold from scratch. I just bought the unfinished log manifold to save some time.

I'm not sure about the ZX2 engine compartment layout, but for the Cougar, it has a motor mount on the front frame which the Focus doesn't have. If your ZX2 has that same motor mount, you may run into some clearence problems using a Focus turbo manifold because of the flange position.

I've heard of the SCT programmable chip. It's probably the best engine management solution for the Zetec.........I just wish they came out with it earlier when I began planning my turbo set-up.........I would probably be using it now instead of the Greddy
E-Manage and MSD DIS-2.

Re:2.0 Zetec turbo
 

Right on, I didn't recognize the JGS with your external WG on it- looks very clean. So far on my mock-up, everything should clear using the Focus mani. Eventually I'll upgrade to a true turbo mani like yours, but in the meantime I'm going to run HMT style.

How much boost are you running? Intercooled? Any problems you've had to work around?

Re:2.0 Zetec turbo
 

my brother has a focus zx3, MBRP SS exhaust w/ K&N Drop in (makes the same power as a AEM).

http://www.cardomain.com/memberpage/346643/8

my CRX site, pics of his focus.

Re:2.0 Zetec turbo
 

Hah, nice setup man.. I had a friend locally who wanted me to do a setup on his Zetec,

great info!

:)

Re:2.0 Zetec turbo
 

Right now I'm running 7 psi boost............the external wastegate spring is set for 8 psi, but with the charge pipes and intercooler I'm getting a 1 psi pressure drop. Actually that's pretty good considering I'm using 2 1/2" charge pipes and a pretty big FMIC. Once I dial in the A/F ratios and ignition timing, I'll see how much boost I can get with 92 octane pump gas. After that, I'm going to set-up a second A/F, timing map for 10-12 psi and race fuel. That's the great thing about the E-Manage/MSD DIS-2 programmable combo.........I can create different maps and save them. One as a daily driver and the other for the track.

The intercooler is a 30" length X 6" height X 3" wide, 8 row, FMIC with 2 1/2" a inlet and outlet. It was the largest size I could fit under the bumper cover without causing clearence problems with the stock foglights.
http://www.fastcougar.com/forums/att.../Inter12%2Ejpg

The only real problem I had to work around was some clearence issues with the oil seperator/PCV valve assembly. You know the one mounted on the front of the engine block. That box sticks out pretty far (about 2 1/2"). I originally planned on using the internal wastegate on the T-3, but there was not enough clearence between the oil seperator/PVC assembly and internal wastegate housing or the wastegate actuator rod. Relocating the turbo manifold flange would put the turbo right up against the radiator......so eventually I had to go with the external wastegate. Other than that, the whole install went pretty smooth.

Good luck on your project..........

BTW.........thanks for the compliments AbaZ....... ;D

Re:2.0 Zetec turbo
 

Nice setup. Good to see some nice home made stuff.

Are you going to publish the maps you are using with emanage with a wiring diagram how to for zetec?

Re:2.0 Zetec turbo
 

Thanks Jono83,
I actually have made a pretty detailed
E-Manage "how-to" for the Zetec Cougar.
It includes pictures and the EEC-V PCM to E-Manage wiring.

http://home.hawaii.rr.com/afterhours124/How-to's/E-manage/emanage.doc

The signal amperage from the Ford wasted spark ignition system puts out a spark out (SPOUT) signal that is much too high for the E-Manage to process. If you try to hook up the SPOUT signal directly to the E-Manage, you'll end up frying the E-Manage ignition circuit. You can build an ignition module using a darlington array IC and a Mitsubishi ignitor module, but I think you'd be better off using a seperate ignition control device such as the MSD
DIS-2 programmable ignition controller. There is also the J&S Safe Guard, which is similar to the MSD.......but can also retard ignition timing based on a knock sensor.