1994 - Ford Escort Cosworth - power steering fluid tank

[jonomisfit]

I think I may well do that.

It also means I don't have wirring sitting next to the hot rad, and ripe for being broken in any nudges it may get.

I think i've also found out where the side lights connections are...

Escort cosworths have indicators in the front bumper, what look like indicators next to the headlights are the side lights.. as per the below




These go for STUPID money (£150+ each...) so a different solution may be required in the interim.

Mot tests says....

"Front and rear position lamps

Vehicles must have 2 front and 2 rear position lamps, except for tricycles or quadricycles that are less than 1,300mm wide.

Daytime running lamps (DRLs) or headlamps may function as front position lamps. "

So I may just wire it up so first stage lights are headlights, not side lights. The side lights can then be blanked off. which appears a common mod when fitting morretti round lights anyway.

[mk2cossie]

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

[jonomisfit]

Its custom wired. The ignition switch is for the ignition only.

The isolator switch does everything else. If it proves to be an issue I can always mount some LED's in the headlight somewhere.

If you look a the picture above you can see the headlights extend into the wing. For normal escorts the headlights end at the wing join line. This makes the normal indicators much wider than the escort/xr3i/rs2000 side lights, as such they don't fit in the space thats left.

I have a pair and if worst comes to the worst I can cut them down to make them all fit. I just suspect it will not look the best.

Or, failing that, I'll fit the set of morretti double round headlights I have, which have the side lights built into them.

[jonomisfit]

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.

[Darkspeed]

Anyone who as owned an old Ford will be more than familiar with a view like that. - And the smell......

[jonomisfit]

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

[melle]

Jul 31, 2020 19:35:53 GMT jonomisfit said:

I need to buy some more junior power time connectors for the Injectors

I recently bought a couple Rover 400 injector looms on eBay for a fiver apiece posted. I searched for "injector loom", selected cheapest first and then kept scrolling until the first loom with JPT connectors popped up.

[jonomisfit]

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.

[melle]

I once bought knock-off JPT plugs and they were rubbish (the plastic disintegrated in no time), so genuine used ones it is for me now. New genuine ones aren't ridiculously expensive either, but I like repurposing stuff if possible. I buy boots from 3 Way Components on eBay (they used to have packs of 10, but I don't see those any more).

[jonomisfit]

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.

[melle]

I have to admit the ones I bought were the cheapest I could find from a UK seller on eBay, can't remember who it was.

[jonomisfit]

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.

[jonomisfit]

some bits arrived.

P1040011 by jono_misfit, on Flickr

so i thought i'd make use of this bit

P1040012 by jono_misfit, on Flickr

I need to make a split collar bulkhead transit for the ECU loom as I'm not taking the ECU connector off the loom. Some CAD modelling.

Something like so, although probably with a couple of hold down tabs rather than the overly complicated and difficult to machine (for me) collar arrangement.

Bulkhead Penetrator assy by jono_misfit, on Flickr

Bulkhead Penetrator assy -2 by jono_misfit, on Flickr

Bulkhead Penetrator assy-3 by jono_misfit, on Flickr

Bulkhead Penetrator assy-4 by jono_misfit, on Flickr

so have to make two of these.

Bulkhead Pen - Piece 2 by jono_misfit, on Flickr

It looks huge, as everythign does in CAD, but for scale its 65mm diam and 50mm long.

Cut a lump off the nylon off.

Chucked it up and started taking some cuts.

P1040013 by jono_misfit, on Flickr

took some more cuts to get it vaguelly the right dimensions

P1040014 by jono_misfit, on Flickr

I forgot how much I don't like cutting nylon.

then very carefully cut it in half.

P1040015 by jono_misfit, on Flickr

but not carefulyl enought as there is a wobble in the middle.

P1040016 by jono_misfit, on Flickr

flattened the faces off in the mill

P1040017 by jono_misfit, on Flickr

drilled and tapped, then bolted together

P1040018 by jono_misfit, on Flickr

Trued it up and started getting it to final dimensions.

P1040019 by jono_misfit, on Flickr

Will finish it tomorrow hopefully.

[jonomisfit]

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.

[jonomisfit]

this is quite a useful document, although its difficult to resolve them in to UK part numbers.

www.motorcraft.com/content/dam/ford-motorcraft/en_us/motorcraft_global/products/wire_sets_wiring/18376-Pigtail-Book-2016.pdf

[jonomisfit]

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

[jonomisfit]

I continued on with the engine harness.

Started splicing the Injector feeds (as bank fired) using an open crimp

P1040040 by jono_misfit, on Flickr

P1040041 by jono_misfit, on Flickr

(macro mode has gone bonkers with the flash for some reason)

and started laying out the loom

P1040042 by jono_misfit, on Flickr

laying out bank two feeds (green bands bank 1, purple bands bank 2)

P1040043 by jono_misfit, on Flickr

open crimp in the tool

P1040044 by jono_misfit, on Flickr

cables carefully fed in and crimp about to be made

P1040045 by jono_misfit, on Flickr

solid crimp tested with a good tug

P1040047 by jono_misfit, on Flickr

two layers of heat shrink added

P1040048 by jono_misfit, on Flickr

then routed on the board

P1040049 by jono_misfit, on Flickr

I don't have a big enought crimp to make all the black connections in one go, so ive staged the crimps on the main feed. I stripped back 10mm of insulation mid wire, crimped on three wires, then stripped insulation at the end of the wire and crimped onthe remainder.

P1040050 by jono_misfit, on Flickr

its not so easy to see in the bad pic

back on the pin board

P1040051 by jono_misfit, on Flickr

then started applying the high temp braid and idents

P1040052 by jono_misfit, on Flickr

more sheathing progress

P1040053 by jono_misfit, on Flickr

then ran out of time for today.

[mk2cossie]

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

[jonomisfit]

If you've got a wirring diagram that would be great thanks.

You like my unique layout on the board :-) I mean, technically i know i could have put the earth up and the injector down... but i'd already written gnd so it had to stay like that.

My big problem is I don't know which bank was the brown wire and which was the brown with a black tracer..

Thanks

I considered one of them, but to get above a 4 channel 1 is £££. Which i don't have :-( so its fuses and relays for the moment. I was going to get miniature circuit breakers / resetable fuses but pricing them up it soon adds up.

If the funds ever rebound from buying the fuel hose fittings then I might get a solid state switch and do a centre console mk2.

[eurogranada]

I think I'm going to steal your idea on that nylon cable thing. I could use one myself.