Duratec vs Zetec Fuel Tank?

[IslandFocus]

Are these two tanks interchangeable?

[polarisman14]

I believe they will bolt up in the same location but you would have to use a different fuel pump/basket/sending unit and I think the line routing may be a little different...You having fuel issues?

[Z63R]

Are these two tanks interchangeable?

The Zetec tanks were, I think, plastic and a 12. something gal capacity. The PZEV Duratec tanks are steel with a 14 gal capacity. You'll need a Duratec PZEV-specific exhaust system, too, due to the muffler sizing in that area.

There may be more than that; more than what meets the eye. I wouldn't attempt the swap without a complete Duratec donor fuel system (assuming you want the larger, steel tank).

[Lancer211]

13.2 and 14, according to this.

Originally Posted by Z63R

The Zetec tanks were, I think, plastic and a 12. something gal capacity. The PZEV Duratec tanks are steel with a 14 gal capacity. You'll need a Duratec PZEV-specific exhaust system, too, due to the muffler sizing in that area.

There may be more than that; more than what meets the eye. I wouldn't attempt the swap without a complete Duratec donor fuel system (assuming you want the larger, steel tank).

[UnFocusedZX4]

Well you won't need a "PZEV" exhaust. It would be a duratec exhaust. However I've seen zetec exhaust on a duratec before. It was a borla system. Tight fit but it fits. Also my duratec fuel tank is plastic on the out side. I do believe the plastic tanks have a blatter in them also.

[IslandFocus]

I am thinking about the possibility of going with a fuel return setp and it was suggested that the steel Duratec tanks can be modified (by welding on a sump) instead of going with a fuel cell.

[UnFocusedZX4]

Hmm maybe I'll have to look at my tank again. Maybe it is just the top of the tank that is steel.

[IslandFocus]

Other sources are telling me that the Duratec tanks will fit the Zetec. I won't need the wiring nor pump so that wouldn't really matter.

[Ja-Red]

I dont see why it wouldnt... I doubt ford would have changed the floor stamping just to fit a slightly larger tank in.

[Lancer211]

Hmmm.... that'd be kind of a nice little mod for long trips. Less than a gallon more, but it's still something. An additional 20+ miles per tank, probably.

[polarisman14]

William, I'd hold on that for a week or two--I'm trying out the ford GT fuel pump with the stock returnless system. I'll let you know what the max power it can hold is and you can decide if you want to go further with your design. Also, if you return the fuel to the filler neck on the tank and use a engine-mounted surge tank and external fuel pump you can keep the stock tank and pump. I have a diagram sketched out on paint that I can forward on if you need it.

[Dtec04]

^^^Eventually some one else will do it. My buddys shop recogized my surge tank right away. He works on exotic cars and said alot of ferrari's come with a surge tank setup stock. It was so easy to, just seems complicated. Its less then meets the eye.

[IslandFocus]

Thanks for all of the suggestions guys! I'm just throwing around some ideas in my head right now so I probably won't be making a decision on it until another couple of weeks or so. I like to do all of my research BEFORE I start spending money

[Dtec04]

Just know that sumps need some kind of a trap to keep fuel from sloshing around. People use foam but it can still run dry when braking or turning.

[polarisman14]

That's why fuel cells are generally used--a lot of them have baffles inside of them to keep the fuel in place. Our tanks have the baskets that the pump sits in which usually keeps full enough to prevent fuel starvation. I decided to go with the GT pump after Dominic on FF told me he got to 350whp on a returnless system with that--that's about the limit of my turbo. He also mentioned he made 380+ with return style, and that's on a stock tank with a drop-in GT pump and a plumbed fuel line.

[Dtec04]

Then thats what he should probably go with. I think he said his goal was 350-400.

[polarisman14]

^^Yeah, I just suggested the GT pump as that's what I'm trying on my setup--I know yours works really well but there are some extra costs included in the rising rate FPR, external pump and mounting hardware, surge tank, etc--I'm trying for the same results with less bank and I figure if it doesn't work out it'll be a useful part for a return system as well. He's also running the zetec and he may have the pre-recall pump if it's an 00--that's an important issue to address if you haven't already, William. Makes a huge difference in the system's capability.

[Dtec04]

I actually might switch to a regular fpr. Fuel pressure is going to be a bit high when I turn up boost.

[IslandFocus]

I converted to an 03-04 tank and pump setup a while back.

[polarisman14]

^^If that's the case then I'm surprised you're running into fueling issues (if you are). Plenty of high-hp duratecs out there on stock fuel systems IIRC, unless you mean 03-04 zetec.

[IslandFocus]

Yes, I mean 03-04 Zetec. Do you guys know if ALL the Duratecs carry the same fuel tank, i.e. hatchbacks & sedans?

[IslandFocus]

I just checked under the car and it seems that the fuel tank sits pretty low as it is. Not sure how low it sits on the Duratecs but it seems that there would be an issue with ground clearance if the sump is about 1.5" to 2" lower. Any other thoughts?

[polarisman14]

Well from what I understand, most people who run the fuel cells put them in the trunk and/or reshape their spare tire well to accomodate it so clearance there wouldn't be an issue.

[IslandFocus]

Does anyone know the height of the stock Zetec fuel tank?

[FocusSportVP]

Also, keep in mind that the 2005 and newer Duratec fuel pumps hold fuel pressure better than the 2003 - 2004 Duratec units. I've seen this many times and upon switching, much better results were achieved.