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Thread: Workshop manual for 2.0L Blacktop mk3 Zetec

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    Workshop manual for 2.0L Blacktop mk3 Zetec

    Hi,
    I am using a 2.0L Blacktop mk3 Zetec for building a Lotus Super7.

    I need to buy fuel line (up and down). which diameter do I need?
    I need a fuel pump (which pressure, what capacity)?
    I want to know which sensor has which function?
    Is there a build in fuel pressure regulator?

    In other words, where can I find/buy a garage workshop manual that answers all those questions.

    Thanks in advance for your advice.
    Cees

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    Re: Workshop manual for 2.0L Blacktop mk3 Zetec

    Assuming a 135hp output and using the standard injection i'd say 6mm ID bore flow and returns - if swopping the injection for ITB's - Jenveys for example then I've upped the flow to 8mm ID on my RS2000 install which should output about 175hp.

    Fuel pump - https://www.fuelpumpsonline.co.uk/sy...017-1931-p.asp - would be fine for this install.

    What sensors are required will all be subject to what the ECU requires / needs to work correctly.

    A Haynes manual for a 2000 / 2001 will detail most of what you'll need for a Blacktop Zetec

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    Re: Workshop manual for 2.0L Blacktop mk3 Zetec

    Hi Katana,

    thanks for your clear answer. I will get the Haynes manual.

    I have a new create engine with fuel rail and sensors already installed. Only no ECU. I assume it will be more cost effective to look for an ECU that matches the current engine. Is that a correct assumption?
    Cees

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    Re: Workshop manual for 2.0L Blacktop mk3 Zetec

    The only ecu that will exactly match the engine without modification or tuning will be the OEM Ford item......not necessarily the best choice as it will require more items from the original car that you will likely not be fitting as it monitors a lot of associated electrical systems and may default to 'fail safe' if it can't find them or it thinks they have failed! And they aren't necessarily tunable for alternative intakes / exhausts etc.
    Most aftermarket ecu's can be reprogrammed / tuned to work with any engine and / or the suppliers will have baseline programs / maps to work with a Zetec B/top and generally will work with bare minimum associated electrical requirements.

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    Re: Workshop manual for 2.0L Blacktop mk3 Zetec

    Pffft, I understand what you are saying. This is exactly why I do not want to buy a Ford ECU.
    I was hoping to buy an after market ECU, hook it on to the different sensors and dial it in.

    but first, I need a proper manual...
    I contacted haynes to buy a manual but they can not help me beause they do not know which of their manuals is suitable for my 2.0i blacktop mk3 Zetec DOHC.
    Any idea which manual this can be?

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    Re: Workshop manual for 2.0L Blacktop mk3 Zetec

    Pffft, I understand what you are saying. This is exactly why I do not want to buy a Ford ECU.
    I was hoping to buy an after market ECU, hook it on to the different sensors and dial it in.

    but first, I need a proper manual...
    I contacted haynes to buy a manual but they can not help me beause they do not know which of their manuals is suitable for my 2.0i blacktop mk3 Zetec DOHC.
    Any idea which manual this can be?

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    Re: Workshop manual for 2.0L Blacktop mk3 Zetec

    if you want an aftermarket ecu why do you need a haynes manual?
    it will either tell you nothing, or loads of stuff which isn't relevant to your installation

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    Re: Workshop manual for 2.0L Blacktop mk3 Zetec

    Thanks for your question Graham.

    I have exerience with fitting and tuning a throttle body system on an V8 from Fordracing. I have no experience with Zetecs.

    Katana kindly gave me the answer to my questions about fuel line and fule pump but I have so many more.
    There are several sensors on the engine which I want to identify. There some parts on the engine where I do not understand the function. Is there a fuel pressure regulator included in my engine? Etc.

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    Re: Workshop manual for 2.0L Blacktop mk3 Zetec

    most zetecs are dead headed on the fuel rail, ie no regulator at the rail and no return, the regulator is attached to the pump in the tank, all you need do is look at the fuel rail to see.

    it would be a lot simpler if you could just post a picture or two of your engine, we could then name bits for you rather than guessing. as far as sensors go, in the main aftermarket ecus only really need, crank sensor, coolant temp and throttle position, if you have a cam senor ( which your engine will have) as well you can have sequential injection too. ideally but not overly important, you want air temp sensor, but the zetec has that incorporated in the air mass meter, which you dont use with aftermarket ecus

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    Re: Workshop manual for 2.0L Blacktop mk3 Zetec

    Graham,

    I hate to ask so simple newbe questions but, I agree, this is the best way now.

    I can not upload pics. Here they are: (link is valid until end of this year.)
    https://cees123.stackstorage.com/s/jhB3rrN4Wad4hL9

    Photo 1 What is supposed to be here?
    Photo 2 Is this the crank shaft speed sensor?
    Photo 3 Is this the crankcase ventilation system oil separator?
    Photo 4a+b Is this low oil pressure sensor?
    Photo 5 No Idea
    Photo 6 Throttle position sensor?
    Photo 7 no idea
    Photo 8 Water temperature sensor?
    Photo 9 fuel feed, return and pressure regulator according to arrows in picture.

    More general pics are in:
    https://cees123.stackstorage.com/s/WIwtKypzT6M4P2k

    Thanks in advance for your answers.
    Cees

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    Re: Workshop manual for 2.0L Blacktop mk3 Zetec

    1 probably an air con compressor, but could be many things, nothing though important to the running of the engine
    2 yes
    3 yes
    4 yes
    5 cam sensor
    6 yes
    7 vacuum pipe for something, not important to you
    8 cylinder head temp, this is NOT coolant temp, that is in the thermostat housing.
    9 yes

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    Re: Workshop manual for 2.0L Blacktop mk3 Zetec

    Hi Graham,

    That is great. With such advise and expertise, who needs a manual?!!
    Thanks.

    I checked the thermostat housing. and added picture 10a, b and c
    There is nothing in sight that looks like a sensor.
    On picture 10a, there is a spot, see marked arrow. Is this the place where a water temperature sensor should be?

    Cees
    Last edited by Ceesdoets; 25-11-2017 at 21:10.

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    Re: Workshop manual for 2.0L Blacktop mk3 Zetec

    BTW, next week Saturday, I will go to a motor mngt instruction class. http://www.bs-autotune.nl/content/view/108/121/

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    Re: Workshop manual for 2.0L Blacktop mk3 Zetec

    Quote Originally Posted by Ceesdoets View Post
    BTW, next week Saturday, I will go to a motor mngt instruction class. http://www.bs-autotune.nl/content/view/108/121/
    Seems like a good course for newbies but they probably want to promote and sell their own stuff too.

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    Re: Workshop manual for 2.0L Blacktop mk3 Zetec

    Quote Originally Posted by Ceesdoets View Post
    Hi Graham,

    That is great. With such advise and expertise, who needs a manual?!!
    Thanks.

    I checked the thermostat housing. and added picture 10a, b and c
    There is nothing in sight that looks like a sensor.
    On picture 10a, there is a spot, see marked arrow. Is this the place where a water temperature sensor should be?

    Cees
    yes , its held in with a metal clip

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    Re: Workshop manual for 2.0L Blacktop mk3 Zetec

    Quote Originally Posted by Miniliteman View Post
    Seems like a good course for newbies but they probably want to promote and sell their own stuff too.
    Yes + yes.

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