New Zetec - Over My Head (PART 2)

[EburgE]

Everybody did a wonderful job expaining the fuel sensor, temperature sensors, and throttle cable, for the Zetec 2.0L, so here's the next set of questions.

 

This picture shows three connectors from the Caterham harness, marked

 

1. B+

2. Fuel Pressure

3. Spare

 

I know what fuel pressure means, but cannot find a sensor on my engine.

 

I have no idea what B+ and Spare mean.

 

Any ideas?

 

http://www.usa7s.com/aspnetforum/upload/1659539796_MoreMysteryConnections.JPG

[breezy7]

Hal : There may be sensors and connectors that are used in the UK that don't get used on a Zetec powered US 7. I have a connection that is B+ but it is a lug connection that goes to the positive side of the battery but it is part of the harness that is supplied by Caterham USA. I have always assumed it feeds a constant current to the ECU since it doesn't seem to be switched to come on with the ignition. There is a fuel pressure switch on the fuel rail feeding the injectors on my engine, it senses when the engine needs fuel and cycles the fuel pump on and off through the fuel pump control module. The UK 7's(at least when I bought my car) constantly ran the fuel pump and the extra fuel was returned to the tank, I had to cap the return fitting on my tank. Looking at the pictures for your engine it looks like the fuel rail has a cap on the rear end so may not be an issue but I would get in touch with your engine builder and ask. I can supply the directions if you need to cap the line. I sourced my engine through Caterham USA and the harness that comes with the engine is set up to connect with the harness supplied with the chassis so I didn't have these issues. Can you give me a description of the wire colors on each connector and where they are located so I can do a little more digging ? Take a look at your assembly guide, there is a wiring diagram in the back and maybe try posting this question on BlatChat.

[EburgE]

Thanks for the quick response. I have not responded sooner because I still need time to digest all of this.

 

Yes, the manual has the engine and vehicle wiring diagrams. Good catch! I did not realize the engine wiring diagram was in there.

 

I has since read that B+ may have something to do with the alternator. I don't know why the connector is that style, but will keep searching.

 

My fuel rail actually has a low pressure return under the blue regulator (red cap in this photo). Will need a fitting to attach to the flexible black plastic return hose on the vehicle.

 

 

 

http://www.usa7s.com/aspnetforum/upload/206721441_throttle-bodies.JPG

[EburgE]

Caterham USA just responded about these connectors. (Cody is awesome!)

 

1. B+ goes to battery positive. May need a new connector.

 

2. Fuel pressure. If I don't have one, I don't need this.

 

3. Spare. Spare for optional sensors that the ECU could use. Don't need.

[EburgE]

The folks at TWM offered to swap out the threaded return fitting from the fuel regulator with barbed one that will mate with the low-pressure hose on the car.

 

[EburgE]

The folks at TWM offered to swap out the threaded return fitting from the fuel regulator with barbed one that will mate with the low-pressure hose on the car.

 

 

Doh! Unfortunately the barb is 5/16" and the car has a 7/32" ID hose.

 

EDIT: I am told the 5/16" barb works fine with the hose, so long as hot water is used to make the hose flexible during installation.

[Al N.]

Harold, you may want to consider coating that little bolt on the top of the fuel pressure regulator with some sort of sealer...I've driven my car in the rain and it's one of only items in the engine compartment that I see with any oxidation on it.

 

-Al

[EburgE]

Thanks, Al. I'll hit it with the wife's clear nail polish.

[JBH]

Harold:

 

My engine is very similar to yours. I have lots of pictures and I am willing to take more if you need help. My car/engine were assembled by Caterham USA, so that may be a helpful reference point if you run into things that don't make sense.

 

Just let me know if you need something.

[EburgE]

Thanks JBH, that would be really very helpful. Two areas you could confirm.

 

First is two wires that come from the vehicle harness, near the fuel line. I assume these are power and starter switch. The manual says the starter switch wire is green and red, but mine is just green. If the manual is wrong, then do these go to the starter power and starter switch on the solenoid?

 

http://www.usa7s.com/aspnetforum/upload/2108174514_MainPowerAndStarterWires.jpg

 

The second are the alternator connections from the engine harness. One is marked Alt. Power. Does that go to the Alternator output as I have it connected on the right? The other is this weird plug on the engine harness marked B+. Assuming that means battery positive, why is the plug so unusual? How should I adapt this and where does it connect?

 

http://www.usa7s.com/aspnetforum/upload/1044991538_alternator-connections.JPG

[MHKflyer52]

Harold,

 

I can not help you with the wiring but that wire that you show as B+ has what is called a single weather pack connector attached to the end and is the male end so if you get the female end and attache it to what ever it goes to you will have a very nice weather proof connector to what ever it goes.

You should be able to buy weather pack connectors at most auto supply stores and the come in all sizes and shapes.

[JBH]

Hal:

 

I am not sure how much help these pics will be. My wiring harness is taped and tied up so it is hard to see the connections you ask about. You can see the wire to my alternator is large. The other end is connected to the starter and that has a similar wire the runs to the battery.

http://www.usa7s.com/aspnetforum/upload/1376233353_Alt1 reduced.jpg

 

http://www.usa7s.com/aspnetforum/upload/1398831668_Alt2 reduced.jpg

 

http://www.usa7s.com/aspnetforum/upload/993066507_Alt3 reduced.jpg

[EburgE]

Thanks, JBH. The alternator photo helps.

 

Can you take a picture of the starter connections?

 

 

Martin, thanks for the tip about the weather-pack connectors. I think I need a "tower shroud with male terminal." How's that for picking up the lingo?

[JBH]

Starter Connections (or at least the best photos I can get)

http://www.usa7s.com/aspnetforum/upload/590157725_starter1 reduced.jpg

 

http://www.usa7s.com/aspnetforum/upload/1104838763_starter2 reduced.jpg

 

http://www.usa7s.com/aspnetforum/upload/153339024_starter3 reduced.jpg

[stevet]

Can anyone imagine this conversation before digital cameras?

 

Good photo's BTW - what cameras are you using?

 

Steve.

[JBH]

Canon Powershot S2

 

I still marvel at all the digital innovations.

[EburgE]

Thanks again for posting the photos. I had hoped to see where the main vehicle power line was connected. I have it connected at the alternator because the starter terminal doesn't have room. (On the starter is the battery positive cable and the cable to the alternator.)

 

I spoke with the engine builder and he said I do not need to use the following connectors that are on the engine harness because my engine does not have these sensors:

 

1. VCT - variable cam timing

2. Fuel pressure

3. MAP - manifold air pressure

 

I think all my wiring questions are answered for now. The ECU still hasn't arrived, so I might have more questions about that when it gets here.

 

Also, someone showed me how to use a test light and a continuity tester (you can see my level of experience with wiring). I might do some spot checking before I try to start the car.