Duratec Zetec-E (2.0L 4-Cyl)

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.


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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