1994 - Ford Escort Cosworth - power steering fluid tank

[jonomisfit]

Toddler_Misfit was asleep early tonight, so I went out the workshop for a bit.

Centre console to codriver panel link.

power / earth feeds

P1040150 by jono_misfit, on Flickr

Signal feeds added (wheel speed etc.)

P1040151 by jono_misfit, on Flickr

braid on

P1040152 by jono_misfit, on Flickr

labelling, connector, and earth ring fitted

P1040153 by jono_misfit, on Flickr

feeds through like so

P1040155 by jono_misfit, on Flickr

[jonomisfit]

brake switch wiring

P1040156 by jono_misfit, on Flickr

P1040157 by jono_misfit, on Flickr

start tidying up the ECU loom, the diagnostic connectrs etc, are no use to me, plus AC switch and few other bits, so the ends are terminated, sealed, and then added to this dead leg should they ever be needed in the future

P1040158 by jono_misfit, on Flickr

then there is a second leg of things I don't need (gearbox kick down, breather canister purge etc.) so terminated, sealed, and added to a second dead leg.

P1040159 by jono_misfit, on Flickr

next job will be sorting out the ECU / Engine loom feeds / relays / fuses.

[mk2cossie]

I havent forgotten about the wiring diagram, just lacking inspiration and motivation at the moment

The wiring looms are coming along nicely tho, very impressed with how good they look
Do you have the AC pump and bracket going spare by any chance?

[jonomisfit]

No worries.

I'm pretty certain the answer to this is going to be no, but i'll check the workshop next time i'm out there as my dad dropped a load of bits off and there could be the pump and bracket somewhere.

[melle]

Any recommendations for braided sleeve? I've always used loom tape or re-used brittle original sheathing on my cars, but what you're using looks so much nicer. Had a look on eBay, but it all looks the same and varies wildly in price. I wonder how well the different types hold up in practice (read: engine heat)? I'd rather use the best I can afford, then redoing it in a few years time.

I like your sub-looms. I was always of the opinion that it was better too have less connections = less potential issues, but with decent connectors it shouldn't be a problem really.

[jonomisfit]

I bought mine from a company called PMG rather than eBay, I can't recommend them enough. The eBay stuff seemed very expensive for the same products.

There are a number of different types. If you look through the pics there are two types I use. The one with the white crosses through it is a slightly higher temperature one than the all black.

You can also get higher temperature again than I've used, abrasive restant, raychem style seal shroud etc. They get pretty expensive though.

I generally like as few connections in a wire chain as possible, however in this instance I'm driven by practicality of being able to reconfigure it all in the future as engines etc change.

I'll keep an eye on how it develops and if any issues arise from it.

[melle]

Thanks, that's useful information, I'll look up PMG. Did you get your connectors there as well?

It makes sense to have at lease a separate engine loom, and I think it doesn't harm to make things like rad fans easily detachable too.

[jonomisfit]

It's pmgonlinecompany.

I got the connectors switches etc. from a number of places.

Automotive wiring products
Car builders solutions
3 way components on eBay
Bad obsession motorsport

Plus a few others

[melle]

I've used 3 Way a few times, always been happy with their products. Will check out the others, thanks again.

[jonomisfit]

ECU loom termination, the main live feed for 02 sensors and Injectors, the ECU power feed, an ignition signal, and the starter solenoid trigger.

The single connector is the tacho signal return from EDIS 6 module.

P1040161 by jono_misfit, on Flickr

[jonomisfit]

I made a central cable guide

P1040162 by jono_misfit, on Flickr

will rivet in here

P1040163 by jono_misfit, on Flickr

temp screwed in , and cable ties fitted to show how its used

P1040164 by jono_misfit, on Flickr

first cable fitted for linking Engine loom to centre panel

P1040165 by jono_misfit, on Flickr

running earths to the relays. I think i'll replace a couple of the rivets with bolts, so I can use them as earth studs, plus it will them properly earth the panel.

P1040166 by jono_misfit, on Flickr

starting the colum loom links.

P1040167 by jono_misfit, on Flickr

loom them up first so they're easier to manage

P1040168 by jono_misfit, on Flickr

P1040169 by jono_misfit, on Flickr

sheath applied

P1040170 by jono_misfit, on Flickr

Terminated and sanity check against the link cable

P1040171 by jono_misfit, on Flickr

When i'm happy with it all there will be coloured banding applied so its easy to see what goes to what.

Its about to start getting really complicated on the wiring front it think.....

I've also decided I need to re-do the feeds to the switches, as most of them don't need to be switched by the ignition, they can just be fed stright from fuses. I've also realised a number of relays arent needed that way and I can use the switches directly for the low load items.

[jonomisfit]

I continued wiring up the panel.

P1040172 by jono_misfit, on Flickr

I swapped out some of the ign feeds to switches and fed some directly from fuses, and then linked some through.

P1040173 by jono_misfit, on Flickr

continued on with wiring up the relays

P1040174 by jono_misfit, on Flickr

and some more

P1040175 by jono_misfit, on Flickr

then worked out I can cut down on the conenction to the board if I split out the front / rear lights from a single panel connection.

P1040176 by jono_misfit, on Flickr

started terminating that through

P1040177 by jono_misfit, on Flickr

P1040178 by jono_misfit, on Flickr

the panel is starting to get very busy... and its only half done.

started on the link loom fom the panel to the bulkhead connector

P1040179 by jono_misfit, on Flickr

black and red split out is the brake switch connection.

P1040180 by jono_misfit, on Flickr

link out loom, the connector on the left of the pic is the feed for the rear lights.

P1040181 by jono_misfit, on Flickr

P1040182 by jono_misfit, on Flickr

Link loom, there will be more wires (a lot more) joining this for things like fans and windscreen wipers.

P1040183 by jono_misfit, on Flickr

[jonomisfit]

a couple of bit tonight, which doesnt look like anything, but tok a while of working out.

the additional cables to add to the loom I've started yesterday....

P1040185 by jono_misfit, on Flickr

suitable sizes / colours found

P1040186 by jono_misfit, on Flickr

prepping for braiding / terminating.

P1040187 by jono_misfit, on Flickr

[eurogranada]

Instead of liking every single post: nice job you're doing on the wiring!

[jonomisfit]

thanks.

Terminating last nights bit of loom.

P1040188 by jono_misfit, on Flickr

wipers, washers, blower

P1040189 by jono_misfit, on Flickr

There were a lot of extra wires for things like washer level sensors etc. which I'm not going to use, so have allocated as some strategic spares.

P1040190 by jono_misfit, on Flickr

task for next time is integrating these two pieces of loom.

P1040191 by jono_misfit, on Flickr

Its going to be a good size....

[petervdv]

Looking good! I like the central guide plate. It makes it look tidy and avoid the risk of pulling of connectors. It is a busy place but should be avoiding electrical gremlins

Peter

[Darkspeed]

Nice work - It does however make me glad I am dealing with very basic circuits with my projects.

[jonomisfit]

I'm hoping so. And also hoping I haven't mucked up anything up...

Hopefully the morris will be more straight forward when I do that

[jonomisfit]

Right, to start conjoining my mess of wires into a single piece of loom

P1040192 by jono_misfit, on Flickr

start layering up the cables

P1040193 by jono_misfit, on Flickr

Start adding in the rest of the cables

P1040195 by jono_misfit, on Flickr


all in a bunch

P1040194 by jono_misfit, on Flickr

It could be a bit neater, and I think the last set I put on should have wrapped the opposite direction.

Added a piece of braid to it

P1040196 by jono_misfit, on Flickr

and started checking the conenctor to make sure the various guages of cables i'm using fit it....

[jonomisfit]

wiring in the rest of the front end connections.

P1040197 by jono_misfit, on Flickr

checking it all lines up with the link loom

P1040198 by jono_misfit, on Flickr

ignition and start wired in

P1040199 by jono_misfit, on Flickr

i then realised i hadnt put in split out connection for the hazzard switch, so had to splice them in

P1040200 by jono_misfit, on Flickr

its all getting very tight...

hazard switch wired in

P1040201 by jono_misfit, on Flickr

flasher relay in

P1040202 by jono_misfit, on Flickr

I then decided to re-route all the ignition feeds to the switches, as its very close to the dash panel and i've already had one cable damaged from it, this way its got much more clearance.

P1040203 by jono_misfit, on Flickr

relay earth in

P1040204 by jono_misfit, on Flickr

I think i'll just add washers / nuts to the bolts holding on the relay panels to get earth points. I'll just nee to make sure they have good contact once its all stripped and painted.

fuel pumps, fuel gauge, and intercom loom.

P1040205 by jono_misfit, on Flickr

P1040206 by jono_misfit, on Flickr

fans feeds added. I'm still undecided on using the existing temp controlling relay or using a new one, so the coiled cables are for the thermostat signal if I do mount them here.

P1040207 by jono_misfit, on Flickr

panel back in situ to check clearance

P1040208 by jono_misfit, on Flickr

its fairly busy in there but it all fits and is accessible

P1040209 by jono_misfit, on Flickr

panel closed

P1040210 by jono_misfit, on Flickr

still a fair space in there

P1040211 by jono_misfit, on Flickr

P1040212 by jono_misfit, on Flickr

I've still got to do the rear loom connections, the bulkhead connector inside and out, and add in a switch panel feed for the co-driver panel. But other than that its getting pretty close to wiring complete...... Untill i need to fault find on it....