Over the past month I have managed to get some time on the car and have been dealing with quite a few electrical head scratchers. The result is that I think I am now down to three main problems - indicator switch puts on the hazard warning lights, the dash powers off on ignition and I need to sort out the wiper motor wiring. There are another couple of small niggles but these are easily fixed.
The big headline, after much angst, is that the engine has finally been started and runs OK. I spent quite a bit of time working out why things were not working only to discover that the pins on the ECU loom plug were not connecting to the ECU pins. A fairly simple fix, removed the pins from the plug, gave then a squeeze with a pair of pliers, replaced them and all connections seem to be OK. Once done, the ECU saw the crank sensor, power was supplied to the coil pack and sparks were present, fuel pump primes, air and coolant temperature were registering and the throttle position sensor was calibrated OK. First turn of the key was encouraging with the engine trying to fire but no joy, swapped the wires around on the crank sensor and next turn of the key she fired up. It ran for a few seconds OK once the throttle bodies were opened up slightly (idle screw) but that was all as there is no coolant in the system. Big result. Once all plumed in I need to check the cam position sensor output and VCT valve operation before starting to do some rudimentary tuning. A big thank you to various car online forum gurus that led me through all of the issues I have had.
The big headline, after much angst, is that the engine has finally been started and runs OK. I spent quite a bit of time working out why things were not working only to discover that the pins on the ECU loom plug were not connecting to the ECU pins. A fairly simple fix, removed the pins from the plug, gave then a squeeze with a pair of pliers, replaced them and all connections seem to be OK. Once done, the ECU saw the crank sensor, power was supplied to the coil pack and sparks were present, fuel pump primes, air and coolant temperature were registering and the throttle position sensor was calibrated OK. First turn of the key was encouraging with the engine trying to fire but no joy, swapped the wires around on the crank sensor and next turn of the key she fired up. It ran for a few seconds OK once the throttle bodies were opened up slightly (idle screw) but that was all as there is no coolant in the system. Big result. Once all plumed in I need to check the cam position sensor output and VCT valve operation before starting to do some rudimentary tuning. A big thank you to various car online forum gurus that led me through all of the issues I have had.
In order to get the coolant hoses in I think I will have to remove the throttle bodies which present an opportunity. I managed to pick up cheap a set of TJ 42mm parallel DCOE throttle bodies and an alloy matched manifold for the Zetec SE. These should give a bit more room on that side of the engine as they are angled upwards more and also give slightly better flow into the engine and better throttle response without messing about with either the pedal pivot point or throttle cable quadrant (on the bike TBs).
Whilst all this has been going on I have finished preparing the trim for painting so will get quote for that. So, there is light at the end of the tunnel and I can start to see the whole project coming together in the next four or five months, just in time for the Ace Cafe gathering in July.
Whilst all this has been going on I have finished preparing the trim for painting so will get quote for that. So, there is light at the end of the tunnel and I can start to see the whole project coming together in the next four or five months, just in time for the Ace Cafe gathering in July.
