In Europe there is a HO Zetec in the Mondeo that puts out 145-150HP. This option sits between the 130 HP Zetec and the Duratec 2.5 V6. I believe the HO Zetec is a Zetec-S with the VCT on the exhaust cam and is similar to the engine that ford put in the ZX2 S/R. (146 HP in federal emissions form.)
If you already have a VCT 'Tour with a 5 speed and a 6-wire MAF you may be able to use parts similar to the ZX2 S/R. The S/R PCM might be available from a wreck or Ford Performance (M-12650-Z2) and an intake (Iceman) and low restriction muffler (Borla) similar to the S/R ought to give S/R level output. Add a UDP, a 180F thermostat and an improved cold air intake and you should be pushing 150 HP. Add the IAT/ECT mod and 150+ HP should be achievable. A tuned header would also be worth +2-3 HP peak and +10 HP past peak in the 6000+ rpm range where the power starts to drop off.
One disclaimer. I don't know anyone who has actually done this so I can't guarantee it would work. I have the ZX2 wiring diagram, but I don't have the 'Tour wiring. I know that you must have a 5-speed, a VCT Zetec and a 6-wire MAF. There may be other requirements.
I have a ZX2 S/R with most of these mods (header isn't installed yet and I have a modified intake with a polished 57.6 mm TB) and have seen 128-132 wheel HP. If this setup could be duplicated in a Zetec 'Tour it would be sweet.
