The ZX2 Zetec as it was picked up from the salvage yard.

Since it's first use in 1996 Ford Contours, the Ford Zetec engine has undergone many revisions and changes. The following is a list of changes from the experience of trying to swap a 2000 ZX2 Zetec into a 1996 Ford Contour. A project that did work, but was eventually abandoned because the goals of the car had changed, and all of the modifications killed the resale value of the vehicle due to issue with finishing up all the accessories installation, error code elimination, and doing so on a budget.

96 Contour vs 2000 ZX2 Zetecs

• The fuel rails are different. The older Zetec engines (up until 1998) had a return-based fuel system with a FPR (Fuel Pressure Regulator). Both of the injectors should be 19lb hi impedance injectors, although a decision to keep the old ones was made to prevent any extra work. Also, the injectors have different spray nozzles. Although swapping the fuel rails is a very easy task and no customization is required. The intake manifolds are pretty much the same.

  

• The exhaust manifolds are different, it was also decided to keep the old one to make the swap easier.

  

• The oil dip stick in the Contour Zetec is in the block. While the oil dipstick in the ZX2 Zetec is in the oil pan (can be seen at the bottom of the pic). No problem, use an oil pan from the ZX2 and everything will be ok and the oil dipstick can be mounted. Not so! The reason will be explained further below.

  

• The idle pulley is mounted different and has a different sized bolt. The details aren't clear why this had to be done at the time, but there was no other way of using the pulley that was available at the time from one on the other.

  

• This is how the oil pan sits on the ZX2 Zetec, much lower than the oil pan on the Contour. Because the Contour oil pan was a simple oil pan, while the ZX2 oil pan was upgraded to a two piece design with better windage reducers. The biggest problem was that the ZX2 oil pan stuck out too much on the side, where the subframe of the Contour would usually run, because the Mazda chassis it was originally designed for had plenty of clearance by the lower part of the engine. Therefore the oil pan from the ZX2 Zetec could not be used, and the original had to be swapped back in. This did not really present a problem except that since the ZX2 did not have a hole for the oil dipstick in the block, this meant that there was going to be no oil dip stick period. A temporary solution was to put a ball valve into the oil drain bolt hole and occasionally use a clear pvc hose to see the oil level by opening up the valve and letting the oil rise in the hose. Quite a crude solution, but it did work, and oil changes were made much easier (though slower).

  

• Different thermostats, due to the way the radiator is set up in the ZX2 meant that the original one had to be used as well. Notice it's broken in the picture below, because they're very brittle and should always be handled with care!

  

• Because the Mazda chassis is different, the motor mounts are as well. In fact, while the Contour would mount with a strange motor mount that would be connected on the front and back of the engine, the ZX2 mounted with one that connected at the center. A special mount had to be fabricated just to support the engine. And despite the clearance, the engine still did not sit perfectly and would have eventually rubbed too much on the subframe. Spacers could have been used with this mount to raise it some more and eliminate this, had the project continued.

  

• The camshaft sensor on the other side of the head, though this should not effect readings and supposedly is ok with the ECU.
• Some plugs had to be changed and a bit of soldering had to be done to accommodate the new sensors.
• ZX2 transmission obviously can't be used if it was pulled with the engine, would require making custom transmission mounts, if the axles and electronics even match up perfectly.
• The original A/C mount has to be used, because the ZX2 A/C compressor mount puts it where the Contour subframe runs.
• The ZX2 engine included VCT (Variable Cam Timing). However this was left unplugged without any noticeable problems.
• For those wondering why the Contour has an EGR system and the ZX2 does not, it's due to the fact that in a ZX2 the EGR is part of the VCT, which overlaps the exhaust valves a little to suck the exhaust gasses back in. This way the intake stays clean.

This project did end up running, and the engine ran strong, however the transmission soon died and it was decided to grab both the transmission and motor as one piece from another Contour, to make installation of the accessories easier. A newer Zetec was grabbed yet again but from a 1999 Contour. Even this, had so many changes. While it fit better than the one out of a ZX2, the exhaust pipe right out of the Catalytic converter had to be welded and extended slightly. Belts were a nightmare to get the right size (no size would fit period) until custom spacers for the alternator had to be made. There were many other issues not even mentioned here, because remembering them all at once is difficult. Unless it's for a project car that won't have many accessories and the time and money permits, switching to a newer Contour Zetec when replacing the engine should definitely be avoided!