11Budlite Posted February 18 Posted February 18 (edited) 5 hours ago, YourEconProf said: Got some more work done last weekend. Pulled and mapped the whole engine harness, and laid out the new harness and got everything ordered (I hope). New finds: the factory crank sensor (and flywheel) aren't there any longer; the car has been using a custom Hall sensor supplied by SDSEFI, so now I'm going to have to fab up a bracket and use the DIYAuto tune sensor like in this link: https://www.diyautotune.com/news/crank-and-cam-sensors/ though I've ordered a harmonic dampener with 36 tooth wheel for a 2000 2.0L Focus, so that should at least be easy. I'm still trying to 100% rule out whether this engine has or can use a camshaft position sensor. Could the hole that the throttle spring is attached maybe be a cam position sensor hole? I see that some Zetec-R did have them, and having one would allow me to run sequential fuel injection instead of batch. The factory cam position sensor is located on the right rear side of the cyl head. See the sensor just beneath the small K&N breather in this photo. This is from a 95-97 model Zetec, but I'm assuming the later versions have the sensor in the same location. Edited February 18 by 11Budlite
YourEconProf Posted February 18 Author Posted February 18 33 minutes ago, 11Budlite said: The factory cam position sensor is located on the right rear side of the cyl head. See the sensor just beneath the small K&N breather in this photo. This is from a 95-97 model Zetec, but I'm assuming the later versions have the sensor in the same location. Thank you! Now I just need to get the plug out (which I have to remove the cover anyway to set up the timing.)
YourEconProf Posted February 18 Author Posted February 18 17 minutes ago, 11Budlite said: You're welcome! Do you have a part number or year number for that sensor? The hole looks identical to the one on my head, but trying to figure out what actual sensor goes there is tough. Thanks in advance!
11Budlite Posted February 19 Posted February 19 Your engine looks like it's from a later Ford Focus Zetec with the plastic cam cover. I think these were used from 2001-2004 IIRC. One of these should work: https://www.autozone.com/engine-management/camshaft-position-sensor
MV8 Posted February 19 Posted February 19 18 hours ago, YourEconProf said: Also, check this brake action. Not sure how to feel about it. https://photos.app.goo.gl/qyZPJqWsL6Y8P16N7 Looks ok to me. Could stand to have the brake fluid changed and rebled. Two circuits with different piston sizes and take up clearance. 1
YourEconProf Posted February 22 Author Posted February 22 On 2/19/2025 at 5:17 AM, MV8 said: Looks ok to me. Could stand to have the brake fluid changed and rebled. Two circuits with different piston sizes and take up clearance. That's good to hear. On my list is to change all of the fluids--oil, trans, diff, brake, coolant as I don't know the provenance of any of it. Would love any suggestions on what to use in the trans and diff!
YourEconProf Posted February 22 Author Posted February 22 Got the schematic done for the engine harness. Now on to the chassis harness... Print Schematic.pdf 1
Vovchandr Posted March 2 Posted March 2 What are the goals for this year? Get it running as is? Swap the harness out? Dyno it at some point in time?
YourEconProf Posted March 2 Author Posted March 2 19 minutes ago, Vovchandr said: What are the goals for this year? Get it running as is? Swap the harness out? Dyno it at some point in time? Get it running. Get it on track at least once. Dyno it for curiosity, probably not Dyno tuned. I’ve already started the new harness and ECU, as I think it’s the quickest path to getting it running.
Vovchandr Posted March 2 Posted March 2 5 minutes ago, YourEconProf said: Get it running. Get it on track at least once. Dyno it for curiosity, probably not Dyno tuned. I’ve already started the new harness and ECU, as I think it’s the quickest path to getting it running. Gotcha. I'm only asking because I'm potentially going to have to redo my harness for my Zetec if I decide to go with a different standalone other than the Pectel. What are you going with? (sorry if you mentioned it, havent read the whole thread). Stock ECU and stock harness seems like it would be a pretty straight forward path.
YourEconProf Posted March 2 Author Posted March 2 8 minutes ago, Vovchandr said: Gotcha. I'm only asking because I'm potentially going to have to redo my harness for my Zetec if I decide to go with a different standalone other than the Pectel. What are you going with? (sorry if you mentioned it, havent read the whole thread). Stock ECU and stock harness seems like it would be a pretty straight forward path. No worries. I'm putting in a MS3Pro Mini (i.e. Megasquirt family) primarily because it's a pretty common ECU, and it will be my 4th or 5th to install. My current issue is that a previous owner put a different flywheel on the Zetec, thus removing the crank trigger, and replaced it with a custom crank pulley that had an odd 4 point timing setup specific to that ECU, which is no longer made or supported. So I'm trying to kludge together a Focus pulley with a 36-1 timing wheel, as the ones for the 2002 Foci with timing wheel don't align with my accessory belt. Further goal is that since this car has ITBs, that I'll add a cam sensor, so I can run full sequential fueling, but I need to get the crank sensor working first. 1
Vovchandr Posted March 2 Posted March 2 (edited) 37 minutes ago, YourEconProf said: No worries. I'm putting in a MS3Pro Mini (i.e. Megasquirt family) primarily because it's a pretty common ECU, and it will be my 4th or 5th to install. My current issue is that a previous owner put a different flywheel on the Zetec, thus removing the crank trigger, and replaced it with a custom crank pulley that had an odd 4 point timing setup specific to that ECU, which is no longer made or supported. So I'm trying to kludge together a Focus pulley with a 36-1 timing wheel, as the ones for the 2002 Foci with timing wheel don't align with my accessory belt. Further goal is that since this car has ITBs, that I'll add a cam sensor, so I can run full sequential fueling, but I need to get the crank sensor working first. I see. You clearly have more confidence in your abilities than me. My adventures with MS3 ended when I put one into my NA Miata, (PNP unit) and the timing was completely off and that's where I left it ~ 14 years ago now or so lol. Runs on stock ECU Did not run on MS3.. Probably a very simple fix. Maybe I'm smart enough 14 years later to fix it? I'll be following your ventures and learning along the way. Very curious to what you'd put down for power with the ITB's. Sounds like there's a bit of legwork still to go in that department. Any chance of you trying to go all the way to NJ for USA7's at NJMP event? It's a great day. Might be a bit too far for just a visit without the car but still a blast to be a part of. Iconic event for any 7 owner. Participants even get to meet the "mighty @Croc " in person. Edited March 2 by Vovchandr
slowdude Posted March 4 Posted March 4 Since its a euro zetec, might be worth looking into the Emerald. I have one. Most tuners here don't know how to use it. It is however super easy to use. Interface is simple and handles a lot of varied euro engines. Base maps are decent. Will definitely need to ride around with a laptop, but not unreasonable to learn and tune.
YourEconProf Posted March 5 Author Posted March 5 On 3/2/2025 at 3:46 PM, Vovchandr said: I see. You clearly have more confidence in your abilities than me. My adventures with MS3 ended when I put one into my NA Miata, (PNP unit) and the timing was completely off and that's where I left it ~ 14 years ago now or so lol. Runs on stock ECU Hang on...you are running a turbo on a stock ECU?!? On 3/2/2025 at 3:46 PM, Vovchandr said: I'll be following your ventures and learning along the way. Very curious to what you'd put down for power with the ITB's. Sounds like there's a bit of legwork still to go in that department. Oh...so much more news coming in the next couple of posts about that. :-) On 3/2/2025 at 3:46 PM, Vovchandr said: Any chance of you trying to go all the way to NJ for USA7's at NJMP event? It's a great day. Might be a bit too far for just a visit without the car but still a blast to be a part of. Iconic event for any 7 owner. Participants even get to meet the "mighty @Croc " in person. Any idea on the dates or sponsoring org?
YourEconProf Posted March 5 Author Posted March 5 So so much that I've learned about the car since connecting with the original builder, @super7guy. In short, the car was listed on BaT twice, and those listings provide a tremendous wealth of information: https://bringatrailer.com/listing/1983-caterham-super-7/ https://bringatrailer.com/listing/1983-caterham-7/ The VIN was decoded by @Croc in an earlier thread: Chassis number decode LCS4190VCLM LCS = Long cockpit 4190 = chassis number VC – Vegantune VTA engine L = Can mean LHD or live axle. Both apply here. M = Marina/Ital axle (live axle) I'm the 4th owner, 37 years with @super7guy, 2 years in Oregon, 4 years with previous Ohio owner, then me. Motor dyno'd at 200hp according to sheets in BaT listings. Specs are: Focus era 2000 nitrided crank; good for 8k, better to keep to 7.5K crower rods J&E pistons (12:1) Esslinger head (17xx) with oversize valves cams just ground by schneider to 236 I 232 E (I 6-8 thou, E 8-10 thou); best to check clearances before hard run enlarged steel pan; doubled swing gates. ram 2300 clutch 6 puck sprung disk special steel flywheel from UK with weights removed to get to 12 lbs; top fuel 1/2" ARP bolts to 150 ft-lbs 1
Vovchandr Posted March 5 Posted March 5 18 minutes ago, YourEconProf said: Hang on...you are running a turbo on a stock ECU?!? Not running per se. Started on stock ECU to partition out the issue. Plus this was a loong time ago. Pretty sure it doesn't know crank position and it needs that entered in somewhere. 1
YourEconProf Posted March 5 Author Posted March 5 5 minutes ago, Vovchandr said: Not running per se. Started on stock ECU to partition out the issue. Plus this was a loong time ago. Pretty sure it doesn't know crank position and it needs that entered in somewhere. Too bad you aren't closer. But if you want to try again, LMK. If it starts & idles on the stock ECU, then getting it to run on a MS3Pro PNP should be super straightforward. Then its about getting it tuned so the turbo doesn't ventilate your block... I messaged you my phone number & email. Feel free to reach out if you want to put that on your to-do list.
MV8 Posted March 9 Posted March 9 Regarding the axle ident, if you take a pic of the side of the diff carrier between the pinion flange and the axle housing, it should be obvious if it is Leyland/Ital or english escort.
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