Stu Posted January 3, 2010 Share Posted January 3, 2010 (edited) A lot of questions get asked about obtaining more power from the Zetec engine so this post should cover the popular conversions and give you an idea on related costs etc. First of all, you have to decide whether you want to stay normally aspirated or go forced induction (turbo or supercharger). The price per horsepower should be fairly similar between the two, but the forced induction engine will be a considerably better performer due to the greatly improved torque curve produced. The torque curve is more important than peak horsepower figures so bear this in mind when choosing a package. The below packages are all based on the 2.0 zetec engine, figures will be slightly lower for the 1.8 (more-so on n/a than turbo) and the 1.6 is not covered here due to poor tuning options. Packages are based on proper solutions offered by proper tuning places, not cowboy antics re-using parts from other cars or bodging it etc. The items listed in each package are the major items for conversion and obviously not an exhaustive list of everything that is required to complete the job. Prices below are for parts only, an indication of labour involved will be bracketed next to the cost figures. Normally Aspirated Options 145bhp Budget Conversion- Engine rebuild- Skimmed head to raise compression ratio- De-cat- Decent exhaust system- Custom RemapCost... approx. £1k (Labour: 10 hrs+) 165bhp ITB/carbs Conversion- Jenvey 40mm ITB package (carbs can be supplemented - will require different fuel system - additional cost)- Aftermarket management (management cheaper if going carbs and not efi)- De-cat- Decent exhaust system- Live mapping by professionalCost... approx. £3k (Labour: 25 hrs+) 200bhp ITB Conversion- Engine rebuild- Forged pistons, steel rods- Ported head, uprated valve springs- Jenvey 40mm ITB package- Aftermarket management- Uprated fuel system (pump, swirl pot)- De-cat- Decent exhaust system- Live mapping by professionalCost... approx. £6k (Labour: 40 hrs+) 200bhp+ ITB Conversion- Engine rebuild- Forged pistons, steel rods- Mega Ported head, double valve spring conversion- Jenvey 45mm+ ITB package- Aftermarket management- Uprated fuel system (pump, swirl pot)- High performance exhaust manifold & system- Live mapping by professional on an engine dynoCost... approx. £8k (Labour: 50 hrs+) Forced Induction Options 185bhp Budget 1.6 RS Turbo Conversion- Source RS Turbo engine / ancilleries- Uprated fuel system- Suitable chip- -31 actuator- Decent exhaust system- Intercooler / pipework etc- Setup by professionalsCost... approx. £2k (Labour: 40 hrs+) 200bhp Budget Zetec Turbo Conversion (See my guide here)- De-comp kit - Uprated fuel system- T25/28 Turbocharger- Turbo manifold- Uprated injectors- Uprated valve springs- Cheap Aftermarket management (eg Megasquirt)- Modified sump for oil return- Decent exhaust system- Intercooler / pipework etc- Setup & mapped by professionalsCost... approx. £3.5k (Labour: 40 hrs+) 300bhp Zetec Turbo Conversion- Area Six Engine Package 1- Uprated fuel system- T34 or equiv. Turbocharger- Uprated fuel injectors- Aftermarket management & custom loom (eg Pectel T2)- Turbo manifold- Decent exhaust system- Intercooler / pipework etc- Setup & mapped by professionalsCost... approx. £7k (Labour: 50 hrs+) 400bhp Zetec Turbo Conversion- Area Six Engine Package 2- Uprated fuel system- T38 or equiv.Turbocharger- Custom inlet/exhaust manifold- Custom cams- Uprated fuel injectors- Aftermarket management & custom loom (eg Pectel T2)- Decent exhaust system- Intercooler / pipework etc- Setup & mapped by professionals- +engine dyno timeCost... approx. £9k (Labour: 50 hrs+) 500bhp+ Zetec Turbo Conversion- Area Six Engine Package 3- Uprated fuel system- T61 or equiv. Turbocharger- Custom inlet/exhaust manifold- Custom cams- Uprated fuel injectors- Aftermarket management & custom loom (eg Pectel T2)- Decent exhaust system- Intercooler / pipework etc- Setup & mapped by professionals- +engine dyno timeCost... approx. £10k+ (Labour: 50 hrs+) Please bear in mind all prices above are rough indications and can quickly increase depending on spec changes and actual labour rates from the providing garage/tuner. On the more expensive packages, tuners will often do a deal on labour rates into the conversion. For zetec turbo engine supply I recommend: Area Six For all Ford CVH/Zetec/YB tuning/custom mapping: Grove Garage & AB Racing Edited February 25, 2010 by PeeWee Link to comment Share on other sites More sharing options...
PeeWee Posted January 3, 2010 Share Posted January 3, 2010 Pinned for future reference. Nice write up. Link to comment Share on other sites More sharing options...
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