1994 - Ford Escort Cosworth - power steering fluid tank

Nice job!
I bought a Dymo Rhino 4200 labelprinter for € 60.-which can print crimping labels for cables. Love it!
Thom

I hope people like pictures of wires, as thats pretty much all there's mainly going to be for a while I think.

Granada cosworth Engine / ECU loom (worth noting the car loom for the granada has about 2x the amount of wires already laid out)

P1030825 by jono_misfit, on Flickr

started sorting through it identifying whats what, whats needed, and whats not.

P1030826 by jono_misfit, on Flickr

i needed to remove some of the wirring from the bulkhead grommet, to do this I need to get connectors through a space thats too small for the bodies, so need to remove the pins. I mean. this bit of loom isnt going to be used, so I could just cut the connectors off.....

connector

P1030827 by jono_misfit, on Flickr

after much examining determined there's latches on the connector pin. needs a removal tool. insert and a light push.

P1030828 by jono_misfit, on Flickr

maybe not exactly the correct tool, but functionally equivalent.

P1030829 by jono_misfit, on Flickr

a light pull and the pin comes out

P1030830 by jono_misfit, on Flickr

and conenctor off

P1030831 by jono_misfit, on Flickr

mark down which colour goes into which terminal....

another type of connector

P1030832 by jono_misfit, on Flickr

slide out the rubber seal

P1030833 by jono_misfit, on Flickr

apply the release tool

P1030834 by jono_misfit, on Flickr

terminals pop out

P1030835 by jono_misfit, on Flickr

slowly getting less wires

P1030836 by jono_misfit, on Flickr

helpfully the ABS loom is entirely seperate from the ECU loom. At least I couldnt find any interconnects. So i have removed in its entirety.

There was no way to get the ECU loom through the bulkhead grommet, and the grommet is about 20mm diam too big to fit the escort bulkhead. I'll machine up some nylon and make a split bush to replace it I think. The escorts one has been cut / torn previously and is hanging together with tape.

getting much more manageable amount of wires. I also started stripping off some of the self amalgamating tape, which is horribly sticky.

P1030837 by jono_misfit, on Flickr

now i'm down to a more sensible amount of wires I can start working out what everything is and tagging it.

P1030838 by jono_misfit, on Flickr

slowly gettign there including using the web to identify what some of the components are (like EGR pressure sensors, vaccume control solenoids etc.)

P1030839 by jono_misfit, on Flickr

took me ages to work out what this curse word is....its the MAF

P1030840 by jono_misfit, on Flickr

There are two connectors go onto the engine, one for injectors, temp sensors, ISCV, etc. and the other for crank sensor, exhaust pressure, air temp, etc. It took ages with a a multimeter and some probles to trace it all through. I thought i was messing it up at one point as the injectors were showing as only using two pins (for six injectors) which didnt seem right. This would mean they bank fire.....

I found an ECU wirring diagram on the web earlier..... the V6 is bank fired. That explains it.

What interesting was how much bodging had gone on on the engine wirring. I think my favourite bits are the connector block to splice a damaged wire to the autobox full throttle kick down sensor, and the repair made to the ISCV wrirring using... connector block and 1mm ... twin and earth...... twin and freaking earth...... including the outer sheath and earth wire...

Just as well i took the manifold off to trace things. I can re-wire this propperly, and also i noticed the fuel feed / return have chafed most of the way through, so I can replace them as well.

Whats good is having looked over the diagram my electrical investigations and assumptions appear to be pretty much on the button.

Its impressive just how much loom isnt needed to run the car.

I also started stripping back insulation on the Escorts car loom so I can re-position the wires to where needed. If for nothing else it gives me a wire length template.

Thanks.

I think a lot of people don't like wiring as it looks complicated and easy to get it wrong. My dad refuses to go near car wiring, anything else he'll happily do, just not wiring.

If your methodical its pretty straight forward. Circuit diagrams really really help though, along with a general sense of what is likely to connect to what.

That said. Being an electrician by trade (in my dim and distant past) followed by a controls system engineer (doing control systems for process plants) probably helps my confidence a bit .

Thanks.

I'm going to be using expandable braided sleeving in the car with heat shrink on joints, connectors, and branches. Which nicely protects, but with care can be opened for changes.

In the engine bay I've found some impermeable heat resistant sleeving so will likely use that, again with heat shrink.

With the state the engine bay wiring has gotten into it's clear careful routing and protection is needed.

I'm definitely going to be getting the right tools for pin fit / extraction and crimping pins.

I may as well do it once and right.

Plus I'll then have the kit for future projects. Most notably the morris and toddler_misfits totrod when it gets started.

Thanks!

For speed I was hoping to get it running using the base ECU and was going to junk it all the EGR stuff as figured it's superfluous.

I shall ensure I don't!

Either that or I'll need to bump phase 2 plans for a stand alone ECU.

I ,

At a guess Idle Speed Control Valve fits

More wires today.

stripped off the loom binding from the escort car loom, which took ages.

P1030841 by jono_misfit, on Flickr

it revealed a number of unidentified random wires that had been cut off.

P1030842 by jono_misfit, on Flickr

Some went back to the fuse panel connector, some were orphaned in the loom.

P1030843 by jono_misfit, on Flickr

pulled back through the loom where they still enter the connector until I can work out they are.

P1030844 by jono_misfit, on Flickr

P1030845 by jono_misfit, on Flickr

not sure why, but the main fuel pump earth ran from an earth point near the fuse panel the length of the car to the fuel pump, rather than pick up near the pump. I'm guessing so a signficant earth is povided the whole length of the loom should there be a fault / it get cut in an accident.

P1030846 by jono_misfit, on Flickr

pulled back everything then started a temorary fit in the car.

Using sticky cable clips. These work nicely as a temporary fitting but need to be screwed or rivetted on for anything longer term as they always fall off in time if just teh sticky pad is used!

P1030847 by jono_misfit, on Flickr

laying out the loom

P1030848 by jono_misfit, on Flickr

P1030849 by jono_misfit, on Flickr

ran the fuel sender and fuel pump feed to the new locations.

P1030850 by jono_misfit, on Flickr

I also changed the main loom routing to the centre tunnel which means I can re-use this loom section into my new arrangement as its shortened the loop and wont need extending.

P1030851 by jono_misfit, on Flickr

I also found a range of other centre console switches that had been cut off and pulled them back.

A fair collection of no longer needed cabling

P1030852 by jono_misfit, on Flickr

Then started on the main engine bay loom

P1030853 by jono_misfit, on Flickr

de-binding the ABS loom

P1030854 by jono_misfit, on Flickr

more de-binding

P1030855 by jono_misfit, on Flickr

continued de-dinbing the rest of the loom.

P1030857 by jono_misfit, on Flickr

Came across many bits like this. No idea what was there, but all cut back and hidden in the loom.

P1030856 by jono_misfit, on Flickr

The loom has been pretty butchered about.

start pulling back all the ABS loom bits. Where I can i'm un-picking through the loom and leaving conenctors on, simply so that I've got as much useable wire for when I need it later.

P1030858 by jono_misfit, on Flickr

bits like this i really don't understand.

This is a signal wire that goes from a splice into the main power feed to the ABS pump (about 100mm from the pump on the engine side of the bulkhead) and runs all the way back to the ABS module.

P1030859 by jono_misfit, on Flickr

the purple relay is the main power feed for the ABS pump. Its mounted next to the ABS module. The big red power feed you can see coming out of it (red with blue stripe is feed in, red is power out... at least in this case) is the same one that runs to the ABS pump where the little red wire is spliced onto it then runs all the way back to the ABS module. It could just loop the 100mm to the ABS module from the relay without a 6m journey down the car and back.

P1030860 by jono_misfit, on Flickr

the only thing I can surmise is, as ABS is a high integrity system, they need to be certain that the pump has a power feed and the signal wire is there near the pump to ensure that you cant really get an ABS pump power feed cable failure / cut downstream of where the signal is taken (at the bulkhead etc.).

there are a number of similar feeds and signals in the ABS part of the loom.

ABS loom starting to thin out a bit now.

P1030861 by jono_misfit, on Flickr

my cable stocks are mounting.

P1030862 by jono_misfit, on Flickr

The main ones for re-use are the power feeds cables.

Good info. Thanks!