Duratec Zetec-E (2.0L 4-Cyl)
Information on the Ford Duratec Zeta (Zetec) engine
General Information
| Cylinders | 4 |
| Displacement | 1989 cc / 121.4 ci |
| Firing Order | 1,3,4,2 |
These engines appear to be very difficult to find rock solid information for!!!!
Ford originally names the engine as a Zeta then changed it to Zetec. From 2003 the name was changed again to Duratec but the Duratec name covers more than one engine family and more than one generation, and different cylinder counts, with more later models being a completely different Mazda designed L-engine with intake VCT and DBW throttle.
So when someone says they have a Duratec 2.0L engine, they need to be very clear what exact variant they have.
Model Variants
Information from Wikipedia
| Features | Phase 1 | Phase 2 | Phase 3 |
|---|---|---|---|
| Cam Shaft Cover | Aluminium | Aluminium | Early: Black Coated Magnesium / Later: Plastic |
| Label on Cam Cover | DOHC 16v | 16v Zetec | 16v Zetec |
| Sump | Single Part Aluminium | Single Part Aluminium | Two Part: Aluminium & Steel |
| Water Pump | Directly Above Crank | Directly Above Crank | Offset to Exhaust Side of Crank |
| Oil Filter | Angled Downwards | Angled Downwards | Horizontal |
| Cam Belt Cover | Plastic | Plastic | Plastic / Aluminium |
| Cam Followers | Hydraulic | Hydraulic | Solid |
All models 9.6:1 compression
SVT Focus version has 10.2:1 compression and gains variable exhaust cam timing for EGR use only. It does not have Intake VCT.
Duratec-RS is a Turbo 2.0L version of this engine
Sensor Information
Crank/Cam Sensor
This engines uses a Crank Position Sensor and a Cam Position Sensor. The crank trigger has 36x teeth with 1x tooth missing and this is incorporated in the flywheel for early models without VCT and on the crank pulley for later models with VCT. Early models have a 1x tooth cam trigger, and later models have a 5x tooth cam trigger.
Early model
Late model
5x cam trigger on the right
Crank Sensor
A Reluctor crank position sensor is used.
Reluctor Wiring
| Pin | Description | Haltech Connection (Trigger 4-core) |
| 1 | Reluctor + | Yellow |
| 2 | Reluctor - | Green |
Cam Sensor
A Reluctor cam sensor is used. This is located near the cylinder 4 exhaust runner.
Reluctor Wiring
| Pin | Description | Haltech Connection (Home 4-core) |
| 1 | Reluctor + | Yellow |
| 2 | Reluctor - | Green |
Trigger Configuration
Ignition Coils and Igniter
The ignition coils on this engine are of a waste spark arrangement with the OEM ECU containing the igniter modules. It is a single unit with all coil integrated. To use these coils with your Haltech ECU you will require an external 2-channel igniter module.
| Pin | Description |
| 1 | Coil- Cyl1+4 |
| 2 | 12V+ Switched |
| 3 | Coil- Cyl2+3 |
Haltech Dual Channel Igniter (HT-020002)
The Haltech 2-channel OEM Igniter is a good choice for this application.
Dwell Time
Throttle Position Sensor
This engine uses a cable operated throttle body with a position sensor.
| Pin | Description | Haltech Wiring |
| 1 | Signal Ground | Signal Ground Black/White |
| 2 | Signal | Spare AVI (AVI-10) |
| 3 | 5V+ | 5V+ Orange |
MAP Sensor
These engines do not come with a MAP sensor.
Use the internal MAP sensor that comes with your ECU. For higher boost levels an external MAP sensor should be used instead, connected to a spare AVI.
Idle Valve
This engine uses a 2-pin BAC (Bypass Air Control) Valve which is duty controlled by the ECU via 1x output.
2-pin BAC Wiring
| Pin | Function | Haltech Connection |
| 2 | Open Signal | Spare Output |
| 1 | Power | 12V+ Switched |
Coolant Temperature
Ford labels the sensor as a Cylinder Head Temperature Sensor. Wiring and functionality are the same as for normal coolant temperature sensors.
Wiring is not polarity sensitive
| Pin | Haltech Connection |
| 1 | Any Spare AVI* |
| 2 | Signal Ground |
An AVI with a selectable Pullup should be used. If not and external 1k pullup to 5V should be connected.
Air Temp
An Air Temperature Sensor is incorporated into the MAF Sensor. if the MAF Sensor is deleted a new Air Temperature Sensor will need to be added to the inlet.
Knock Sensor
| Pin | Haltech Connection |
| 1 | Knock Signal |
| 2 | Signal Ground |
MAF Sensor
Although most users of Haltech ECUs will be deleting the MAF, it is possible to use a MAF if you prefer.
| Pin | Function | Haltech Wiring |
| 1 | Air Temperature Signal | Spare AVI with Pullup |
| 2 | 12V+ Switched | 12V+ Grey/Red |
| 3 | Sensor Ground | |
| 4 | Signal 0-5V (AVI) | |
5 | ||
6 | Air Temperature Ground | Signal Ground Black/White |
O2 Sensors
These engines come with 4-wire heated narrow band sensors.
| O2 Sensor Wire Colours | Haltech Connection |
| Black (Signal) | AVI 1 or AVI 6 |
| Grey | Signal Ground (Black/White) |
| White | 12V+ Switched |
| White | Chassis Ground (not Signal Ground) or Spare Output |
It is possible for the ECU to supply a duty signal to the Heater Ground, with many OEM ECUs doing this. Haltech ECUs can also perform this task and a spare Injector or Stepper Output should be used.
O2 Sensors can use various wattage heater elements, with 12W and 18W being common. For 18W units it is advised to not supply more than ~50% duty to prevent excessive current being applied to the ECU output.
For post-cat sensors it is advised to not enable the heater ground control until the engine is at full operating temperature. This is to prevent moisture in the exhaust from a cold started engine from damaging the heater element. Many OEM strategies involve not enabling the heater until the engine have been driven above a set speed for a set amount of time.
Adding a Haltech Single-Channel Wideband WB1 Kit (highly recommended)
For correct operation a Haltech WB1 kit is highly recommended for this application, with the provided 4.9 sensors replacing the pre-cat sensors. Sensors use a 22mm socket or spanner to remove and replace.
Vehicle Speed Sensor
This engine uses a Hall Effect Vehicle Speed Sensor.
Hall Effect Speed Sensor
| Pin | Description | Haltech Connection |
| 1 | Signal Ground | Signal Ground Black/White |
| 2 | Signal | Spare SPI or DPI |
| 3 | 12V+ | 12V+ Grey/Red |
OEM ECU Information
ECU Pinout
Component Location
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