Help with CAS

[TuRBoTaLooN]

So I was going to tune taloon for Sunday, but she didn't start up this morning. I got a CEL for cam angle sensor circuit malfunction. I took the timing belt cover off and took a look at the cas. It looks 100% fine, the wiring looks good, and it's plugged in. I tried unplugging the battery to reset the ecu, nothing. DSMLink had "Invert CAS" on (as a default). Tried changing it to off (no invert) and nothing. Pulled the plugs and they were wet with fuel and smelled like fuel. So I went out and bought new plugs and wires and put them in. It started right up!! Hoooray!!!

So I go to put the timing belt cover back on and button everything up. Then I go to start it again to fully warm up so I can tune it. However, it doesn't start. I get the same thing I did before!

Basically it kind of sputters for a half second and then stalls if i let the key go, or the starter just keeps spinning if I hold the key. Sometimes I can get it going a little if I give it enough gas, but it sounds like a frickin lawnmower! Then it eventually stalls out.

Please help! I'm assuming I need a new CAS, but I'll need to find one tomorrow and have someone help me take the intake cam gear off and timing belt so I can replace it. Can anyone PLEASE help me??? I need to get it running for Sunday!

Background information:
1995 Talon, 95 ECU, so the cas is behind the intake cam gear...not on the pass side of the motor.
Just recently installed BC 272/272 cams, revised lifters, arp head studs, new timing belt and components, water pump, all new belts.
Mods are in my profile but:
FP3150
3" exhaust
Stock 2g MAS
FP 4" intake
FMIC
PTE 780cc
255 lph

Any help is much appreciated. Thank you all. You guys have been great so far on this site!

 

[TuRBoTaLooN]

I decided to go with a 1g CAS in my 95 for two reasons.

1) Easier to install. I don't have to remove the t-belt and cam gear to get to the stupid thing.
2) I can now adjust timing via CAS

I'll be picking up one later today and installing it. I will try to take some pics so this post can be used as a reference for those looking to put a 1g CAS in their 2g either because they did a 6 bolt swap or because they don't feel like replacing the stocker behind the intake cam gear.

 

[Rob10_99]

Is that 255 recently installed too? you WILL need an aftermarket FPR for it.

Any fuel pressure gauge on your rail/filter yet?

 

[TuRBoTaLooN]

Is that 255 recently installed too? you WILL need an aftermarket FPR for it.

Any fuel pressure gauge on your rail/filter yet?

Sorry, forgot to mention that I have an FPR with gauge. I've set it to ~43.5psi as per recommended.

 

[TuRBoTaLooN]

Well I started this process of installing a 1g CAS in my 95, but had to drive 100 miles round trip to pick up the part and it was late, so I'll finish up tomorrow hopefully. Here's what I got so far:

First, the 94-96 cars (correct me if I'm mistaken) have a separate cam angle sensor and crank sensor. Like every other car has them both on the passenger side of the head.

Here is where the CAS is located on these cars:

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Closeup:

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You'll first have to make a wiring harness to connect the 1gCAS to the cam angle sensor and crank sensor connector. (Link on how to make this harness: RRE Instructions) step 1 is to cut the wiring harnesses for both. Cut them so you have as much wiring as possible to work with as you have to route the wiring around the back of the motor. Here's where I cut the cam sensor:

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This is what the connector looks like for the cam angle sensor:

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Here's the whole pigtail I cut off.

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If you're still confused as to where these connectors are, they are both mounted on a metal bracket behind the motor by the firewall. Here's a picture of both pigtails mounted on the metal bracket:

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These are the connectors that go to the wiring harness:

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This is where I cut the crank sensor:

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More to come after I finish the install.

 

[kenamond]

2ga CAS is like yours. 2gb CAS is on the end of the intake cam like a 1g, but the sensor is completely different. When my CAS died, it would work then not work. I finally figured out it was the CAS by wiggling the connector. Every time it would act up, I'd pop the hood and wiggle the wire, and it would start. 2gb CAS takes 30 seconds to change. 2ga looks like a bi***.

 

[TuRBoTaLooN]

That's correct. That's why I wanted to make a tech article for the 2ga guys who want to put in a 1g cas. There is a little more to it. Plus pictures always help. If I were to replace my cas with the same one, I'd have to remove the intake cam gear...and thus remove the t-belt. Plus putting in a 1g CAS allows me to adjust timing.

 

[TuRBoTaLooN]

Ok, so she's all done and timed!!

Once you make your wiring harness, you have to remove the plug on the passenger side of the head where you are going to install the 1g CAS.

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To do this, you must remove the valve cover. Most of you have probably done this by now. Remove the spark plug wires, take out the spark plugs, and remove all the inside and outside bolts on the valve cover and remove. If you havn't taken it off in a while you may have to pry it open. Now would be a good time to get a new valve cover gasket set...especially if your old one is worn.

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Here is the motor with the valve cover off. You have to remove this cap to get out the plug. Just take out the two 12mm bolts.

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Here's the cap out and the plug out.

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Here's the camshaft without the plug. You can see a slot where the CAS will go into.

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Now, jack up your car. Take off the front driver's side wheel. Remove the plastic so you can see the crankshaft pulley. Take a ratchet wrench and turn the motor CLOCKWISE so that the motor is TDC. Basically there are marks on the cam gears that you want to point towards each other. The mark on the exhaust cam gear (towards the front of the car) should face 3:00. The mark on the intake cam gear (towards the back of the car) should face 9:00. Shown below:

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Now you have to set the 1g CAS to the right position. I can't seem to find the right words to describe what I want to say, so I'll do my best. But on the cas (shown below) the slot has one notched side. Also, the circle under it has a notch in it. You want to match up these notches.

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Once you've lined this up, attach the cas to the camshaft in the slot at the end. Re-install the cap over the cam with the two 12mm bolts and torque to spec. Bolt the cas to the head. Make sure the bolt is in the middle of the slot for now. In the picture below, it's at the end, but you should have it in the middle to start.

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Now go ahead and put the valve cover back on, and put your spark plugs back in. Now to use this cas you have to reverse the order of the spark plugs. From left to right, your cylinders are 4-3-2-1. The normal setup of spark plugs into the coil pack from left to right is 4-1-2-3. You need to reverse this so it is 3-2-1-4. In DSMLink make sure "Invert CAS" is selected. I'm not sure how to do this without DSMLink, so someone please post up if you know what to do. Connect your wiring harness to the new 1g CAs and to the crank angle sensor and cam angle sensor on the wiring harness.


Now you have to set base timing again which should be 5 degrees advance. You will need to use a timing light. Follow proper directions for using a timing light. To adjust timing, simply loosen the bolts on the cas so you can rotate it. Rotate clockwise to decrease timing, and counterclockwise to add timing.

Now you're done!!