MikeE

I've been asking for advice on the wiring up of my new Emerald on this thread here So yesterday I start looking at the wiring and before I do anything with the 7 wires described in the other post I think I'll just try turning the engine over. So I turn the key and the fuel pump starts whirring away despite the fact I hadn't connected the two fuel pump and relay wires described in the other thread. So first question is how? And also why do I need to connect the pump via the ECU and the Emerald fuel pump relay anyway? Clearly the pump is being fed with an electircal supply but is it possible there's insufficient current to provide the required fuel pressure as I don't believe there's a relay in the circuit? So I then connect the Emerald up to the 12v switched supply and the red LED comes on, I use the SAME 12v switched supply for the ignition and fuel pump relay inputs on the ECU. I then try starting it up and it turns over, the Emerald LED flashes Red and Green (so it sees the engine rotation?) but it won't start So I then take a plug lead off and hold it against the exhaust primary and turn over again and I can see a very small spark. Given I have a (small) spark and think I'm getting fuel to the fuel rail I don't understand why it won't start, I guess I either don't have sufficent supply to either the fuel pump and/or ignition. TOTALLY confused and starting to panic now as my Emerald mapping sessions is Thursday next week If anyone can give advice or better still anyone in the local area can pop over I'd REALLY appriate it *thumbup* cheers R400 Duratec Build and Modification Pictures here Edited by - MikeE on 7 Sep 2007 12:06:12

my quaife allow case came with a shallow head bolt which I can get a ring spanner on - much easier than the old cut down allen key I used to use No I don't have any insulation and I'm starting to think I should! R400 Duratec Build and Modification Pictures here

Rob, Yes Emerald supplied the full 8 injector loom Brent Problem is I have all the Emerald manuals (I checked the downloads on the Emerald site and there's no more info on there) - it explains what the 36 pins do but I don't know where the 7 wires above relate to those pins - for example there are numerous yellow wires on the 36 pin plug so which one is the yellow one mentioned above?!?!? Would appreciate it if I could take a look at your car, well the best I can as I appreciate you don't wont to disassemble it for me 😬 oh BTW I don't seem to be recieving blatmail again so if you have any info please email to mikeedgeuk AT hotmail DOT com cheers R400 Duratec Build and Modification Pictures here

Anyone? I'm getting desperate 😳 R400 Duratec Build and Modification Pictures here

Paul I have a new road and track box with Quaife alloy case - assume it's the same as yours - which I just installed in the car. As it happens I filled the box up today without a problem, just got a length of plastic windscreen washer bore hose, taped it to the bottle of oil nozzle and fed it down the side of the box into the filler hole. Put the bottle upside down in the engine bay and cut a hole in the base of it to let the oil drain - took about 30 mins to get a litre in I'm intrigued why you cant top yours up R400 Duratec Build and Modification Pictures here

Don't know if this is true or relevant but I was told last week that the Duratec runs hotter than a K and therefore if you're doing a k to Duratec engine swap and are going to reuse the 6 speed box then you have to replace the front seal with one which can cope with the extra heat I realise you have a BHG box but if there's any truth in the above then maybe your front seals gone? Of course there's the four bolts inside the bell housing but those coming loose wouldn't cause a leak so the only other possibility is a cracked case? R400 Duratec Build and Modification Pictures here

With only 2 weeks to go to the RR mapping session I really need to get the new 2.3 Duratec and new Emerald up and running in the next couple of days. I've got the Emerald wiring loom in and all the sensors attached but can't figure the wiring at the ECU end - not helped by the fact there doesn't seem to be a wiring diagram in the user guide So when I removed the old Webber Alpha ECU and loom I marked up 2 wires under the dash as follows: 1 - Switched +ve for ECU supply 2 - Tacho ECU supply I also have a black wire next to the battery with a bullet connector on it and I've marked it 'Fuel Pump -ve from ECU?' so obviously I wasn't sure what it was when I disconnected it 3 months ago! Also there's a round connector comming off the main ECU end of the loom which has 7 wires comming off it (green, yellow, white, purple, red, red and orange - without any connectors fitted) and I have no idea what they're for And finally I have a connector call BARO which I assume is for at atmospheric pressure sensor which I don't need? Ideally I'd like to be able to compare my wiring with another Emerald & Duratec car - CAN ANYONE HELP PLEASE 🤔 🤔 R400 Duratec Build and Modification Pictures here

Thanks Rob - need to know the exact type and bracket as I want to source it in the next couple of days as I have the mapping session booked in 2 weeks and running out of time!! Anyone know the spec? R400 Duratec Build and Modification Pictures here Edited by - MikeE on 27 Aug 2007 11:14:10

thanks Peter thats what I was hoping to hear so another question whats the much smaller outlet on the top of the regulator, some sort of breather? and if so doesn't this need to be at the top? R400 Duratec Build and Modification Pictures here

Fitted the fuel regulator to the new Duratec today. The regulator has the input feed in the side and the output (to the fuel rail) coming out of the bottom. The easiest way to mount it would be with a very short output hose directly onto the fuel rail - but if I do this the regulator will be laying flat instead of upright. Is this ok or do they have to be mounted upright? R400 Duratec Build and Modification Pictures here

In the final stages of the installation of the new 2.3l Duratec and one of the final jobs is finish the cooling system. I've seen a lot of Duratecs with a header tank mounted in the centre of the bulkhead - where's the header tank from and what's the fixing bracket/method? R400 Duratec Build and Modification Pictures here

mines fine you wimps 😬 R400 Duratec Build and Modification Pictures here

Thanks Daren - will give them a try R400 Duratec Build and Modification Pictures here

I'm in the final? stages of the Duratec transplant and need to source 2 or 3 rubber caps to blank off a couple of water inlet/outlets on the engine. Does anyone know where I can source these? thanks in advance R400 Duratec Build and Modification Pictures here

I need to get on with my Duratec 2.3l transplant and one of the outstanding issues is where to mount the stack water temp sensor - I'm going to put it in the coolant outlet block at the back of the engine but need to remove, it and drill and tap the appropriate sized thread - I need a 1/8NPTF tapered thread in there? If anyone has the appropriate tools/skills/advice I'd appreciate it - thanks! R400 Duratec Build and Modification Pictures here

But my 'small' Duratec alternator has Brise written on it R400 Duratec Build and Modification Pictures here

Talk to Raceline about this 12 months ago and they were suggestion a cradle that bolted to the back of the diff and the rear chassis rails, that should be a straightforward solution without requiring major surgery? R400 Duratec Build and Modification Pictures here

Well then you'd better carry a spare inertia switch as well you clumsy git 😬 Danny as you well know I'm far too busy slaving away every hour of the day (directing my team of computer geeks) to spend time on my car Dave I have no idea whether the alternator works or not, it's sat in a box somewhere in the garage along with all the other bits I've forgotten how to reassemble 😳 R400 Duratec Build and Modification Pictures here

-ve discount presumably R400 Duratec Build and Modification Pictures here

it's all academic if I can't find the fcuking time to actually put the engine back in the car 😬 R400 Duratec Build and Modification Pictures here

My 2nd one (1 trackday old 😳) has apparently been diagnosed with a 'failed brush pack'??? R400 Duratec Build and Modification Pictures here

Raceline put it in the oil filter adaptor plate.... R400 Duratec Build and Modification Pictures here

Agree with everything you say Ammo but...there has to be an argument that the s/c engine would require less maintenance/rebuilds for the same (320bhp) power levels as you're not having to rev it as hard? (7.500rpm vs 9,800rpm) R400 Duratec Build and Modification Pictures here

as you know I've had 2 fail this year, first was the windings went on the first one, the 2nd only managed 1 trackday and I'm yet to find out what the problem was with that one. R400 Duratec Build and Modification Pictures here

LOL 😬 😬 Although bizzarrely it seems Carbon Fibre requires immense talent to produce, surely it's just like fibreglass with a bit of black dye??? 😳 R400 Duratec Build and Modification Pictures here Edited by - MikeE on 13 Jul 2007 11:12:29