Got any pictures of the Grill block? I'm thinking of doing that this weekend. The cold has been killing my mpg's and I need to gain a little back.
TeamZX2 has a great pcm chart showing which wires are which, it can be very difficult to find the correct wire, but it will work nicely when it's done right. Most say, and I'd agree with the 10 ohm resistor, it shifts like it should have from the factory, firmer...like it means it, vs. the sometimes long shifts that you'll get with out it. I'd encourage you to try again. Did you get the right part number of resistior? The big sand looking rectangular box?
If you gonna drop your A/C then you might as well get a manual rack while you are in there. It's not a difficult job and you can gain quite a bit.
I should be able to to better than 45mpg on the highway right now, my best single day commute was 43mpg with very little stop and go.... a very rare day around here. There are about three guys on TeamZX2 who've gone over 50mpg. None with aero mods, all motor and pcm mods. Mechanically, the Zetec seems to be pretty effcient for mpg stuff. To really get that last bit from the motor, you'll need a full header and exhaust. The stock exhaust pipe is 1-7/8", way to small for what we are doing, you'll need at least 2.25 to see any gain. Mine is 2.5 to the cat back, then 2.25 to the rear.
The hit and miss for the IAT resistor is silly. The guys who it was a miss on were not controlling the variables. Do it
Might want to wait for temps above 70 degrees if you want to document the change though...
The knock sensor doesn't seem to effect everyones car the same. Mine would surge while cruising, and unplugging it stopped the surge. I cruise under 3K, but power over 3K was noticable.
Yep, the Keeman will make it sound a bit more throaty. I'd be interested to see how much, if any, that helps your mpg. I did mine way before I started tracking.
Keep at it, there's no reason you can't get a ZX2 over 50mpg.
For this coming year I am hoping to get some light wieght wheels, 9 lb vs. 18 lb stock steelies, manual rack (mines starting to get some wear and needs to be replaced anyhow), Sealed Ram Air, and Grill block, Home Depot Lip and mud flap delete may happen this weekend though. Keeping my A/C though, because it still works perfect after all these years. My goal is to be up to 40mpg average on my commute by summer time next year, which should get me close to 50mpg pure highway.