1994 - Ford Escort Cosworth - power steering fluid tank

Only that won't work for position lights, as they need to be a separate low output checked with the ignition off

How much are clear indicators for the normal escorts?
Or even use the normal front indicator unit with a 5/21w bulb, side light and indicator in one unit that way

It was hot which was removing a lot of my enthusiasm today.

i finished braiding the exterior engine loom

P1030983 by jono_misfit, on Flickr

the routed it round the engine bay again to check it'll work OK.

P1030984 by jono_misfit, on Flickr

P1030985 by jono_misfit, on Flickr

P1030986 by jono_misfit, on Flickr

Should all work out ok. I need to buy a few bits and make a couple of things before I can finish it up though.

So stripped the last bit of loom out, the on engine loom that has key sensors and fuel injector connections.

P1030987 by jono_misfit, on Flickr

It is knackered. If for no reason than cables are baked, the insulation is going hard, and all the cable protection sleaving has gone brittle and is flaking off.

And then you get to my favourite bits....

the previous repairs to idle speed control valve wiring.

P1030988 by jono_misfit, on Flickr

At least they used connector block and insulating ta..... hold on..... thats green masking tape....

Looking at it some of the insulation looked freyed on the earth wire. I'll just follow that back..

P1030989 by jono_misfit, on Flickr

Uh huh..... theres no insulation left on that bit... protected by the sleave only. I'll just follow it back...

P1030990 by jono_misfit, on Flickr

Uh huh.... there's no insulation on the wire still and there's a molten mass of plastic where it used to be...

P1030991 by jono_misfit, on Flickr

Uh huh... it just keeps going...

P1030992 by jono_misfit, on Flickr

none of that looks healthy. I'm very very surprised this engine was still running before we took it out of the car.

Thats had a very decent short, with a decent sized load on it for a decent length of time. The loom is well and trully knackered on the injector leg! Definitely need to make a new loom piece.


So pegged out the existing loom like some extra from an alien autopsy.

P1030993 by jono_misfit, on Flickr

I need to buy some more junior power time connectors for the Injectors, and a couple of 8 way water proof connectors for the jump back the the other loom.

like a cat thats been on the BBQ too long....

I just bought a couple of packs of 4 from an electrical supplier.

I think it was £7 for 4 including all terminals, seals, and boots.

My only concern with re-use of looms is around if the heat cycles on the engine have degraded the insulation. Admittedly most don't route the wiring in the oven that is the v6 valley


I have had to buy a crimp tool though as the one I have isn't right for JPT pins.

But I needed that no matter which way I went.

I'll give these a good look over when they arrive and see what I think of the quality.

There were other JPTs on eBay that looked a lot cheaper made so figured they were definitely stay away ones.

started unbinding the engien loom and checking for further damage

P1030999 by jono_misfit, on Flickr

the rest of it was fairly OK, although there were a few wires with nicks in them.

P1040009 by jono_misfit, on Flickr

Just waiting for the bits now.

I measured up a few things and made a list of more bits I need to get.

The thought i better finish off the last bits of cable routings.

marked out some steel

P1030994 by jono_misfit, on Flickr

trimmed and folded to make this

P1030995 by jono_misfit, on Flickr

and another one

P1030996 by jono_misfit, on Flickr

then welded them in

P1040001 by jono_misfit, on Flickr

P1040002 by jono_misfit, on Flickr

these are stiffeners for where the cables will go through the panels. Most likely overkill, but I want somewhere for the grommet to hold onto properly.

then made their bigger brother up, which is the transit strengthener for where the fuel connections will go

P1030998 by jono_misfit, on Flickr

P1040003 by jono_misfit, on Flickr

it was really not easy to get into and I couldnt see what I was welding. Lesson learned and I should have fitted this before I welded in the box side.

then started on the fuel line routing

Drilled some holes in the seat mount / floor brace

P1040005 by jono_misfit, on Flickr

P1040006 by jono_misfit, on Flickr

then opened them into a slot with the die grinder, again... note to self do this before fitting seat rails in the future...

P1040007 by jono_misfit, on Flickr

P1040008 by jono_misfit, on Flickr

I've still got to make a flange / strengthener for them.

Looking on the pics of a number of group A escort / wrc cars I can find, they just cut the last 100mm of the seat rail out to let the hoses pass through. I think retaining be a bit better.

I then did some tidying up and thinking about bits I need to do to get to paint.

I finished turning the profile, but its not as neet as i'd like.

P1040020 by jono_misfit, on Flickr

I messed up on the dimensions slightly so the cap head set screws and just sitting proud, or would be it I hadnt nudged the corner off. And I got the latereal distance wrong on one as its broken through as well.

P1040021 by jono_misfit, on Flickr

And in two halves.

P1040022 by jono_misfit, on Flickr

fits like so

P1040023 by jono_misfit, on Flickr

P1040024 by jono_misfit, on Flickr

once bolted up it'll be bound to the loom. I still need to make a couple of mounting tabs for it when I come to fit it.

maked up for bulkhead power transits

P1040025 by jono_misfit, on Flickr

drilled and bolted in

P1040026 by jono_misfit, on Flickr

I'm going to turn up a litte collar / terminal mount for the ground conection, which will be welded onto the bulkhead

took the dash back out and removed the Airbag module

P1040027 by jono_misfit, on Flickr

which gives a good mount for a trip meter or something else.

P1040028 by jono_misfit, on Flickr

There's just not enough space in the centre panel I made up fitting inside the existing cut out. Looking on line at Grp A cars the just cut out the whole lower dash and re-make. I'm going to start with a bit of a trim and see how I get on.

P1040029 by jono_misfit, on Flickr

P1040030 by jono_misfit, on Flickr

there is now a lot more space, hopefully its enough!

P1040031 by jono_misfit, on Flickr

Dashboard pad back in

P1040032 by jono_misfit, on Flickr

then started on the engine wiring loom as some bits turned up in the post.

main loom connectors are going to be removed and replaced with a differnt type as I have looked but cant find the terminals for this.

P1040033 by jono_misfit, on Flickr

P1040034 by jono_misfit, on Flickr

There's a red cover inside that gets pulled out, then you lift a tang and slide out each terminal. note the fretting on the black wire (which is either main switched live, or main ground)

P1040035 by jono_misfit, on Flickr

P1040037 by jono_misfit, on Flickr

P1040038 by jono_misfit, on Flickr

Crumbly / burnt old injector cabling removed and started running in the new wires.

P1040039 by jono_misfit, on Flickr

The Junior Power Timer connectors I orded up arrived and they seem pretty decent quality. The feel as robust as the ford ones, and fit nicely. They have a decent thickness of clip wire as well. Hopefulyl they are good.

I've mocked up a few centre console designs, but this is the current lead design.

Centre Console 2 Assy 1 -1 by jono_misfit, on Flickr

Centre Console 2 Assy 1 -2 by jono_misfit, on Flickr

I might rotate the relay holders through 90 degrees and run the batter cable down the centre of the console.

I also checked the space of the ignition / starter panel.

Centre Console 2 Assy 1 -3 by jono_misfit, on Flickr

Although I'm not certain, I have a suspicion that Ford wired cylinders 1, 3, and 5 as one bank, and 2, 4, and 6 as the other

I can dig out the wiring diagrams I may have to check if you like?

Liking the look of the centre console tho
Have you thought of using a solid state isolation switch? More expensive than the console mounted one, but easier to fit in remote places without a cable to route