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Zetec into a bay
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Superleggo
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Joined: 12 Nov 2009
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Location: United Kingdom

PostPosted: Wed Feb 15, 2012 10:15 am    Post subject: wiring. Reply with quote

I got hold of a copy of Autodata which is not bad then someone gave me a copy of the Ford TIS. PM me your details and I will send you the relevant parts if it helps.

Beware ford change colours and pinouts form model to model but with the wiring diagram it is not too bad to work out.

I plan to redraw the Zetec one when I have finished for my own trouble shooting at a later date. I will publish it one here if it helps anybody.
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T2 turbo
Padawan
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Joined: 19 Jan 2009
Posts: 89

PostPosted: Wed Feb 15, 2012 7:58 pm    Post subject: Reply with quote

I don't venture into the ford conversion section much but just noticed this as my dad is fitting one of these black top zetecs into a mk2 cortina using a megajolt ecu on bike carbs the wiring for that is a peice of piss and the ecu itself is less than 200 if fancy a different root to your wiring nightmares,
Nelly.
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Superleggo
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PostPosted: Thu Feb 16, 2012 6:16 pm    Post subject: Megajolt Reply with quote

T2 - Thanks for the suggestion I have considered the Megajolt/ carbs option but really want ot go down the injection route for all round driability so are going to presevere with the learning curve.

Does your father know that you can get spark converters for the Zetec coil pack for approx 30 which will allow you to run carbs. Much cheaper than a Megajolt. They are used by all the guys banger racing Mondeos. They also use a down draught Webber or bike carbs. All the bits are available on our most loved internet auction site. Could save him 150+

I think I have cracked the wiring just can't find time to get in the garage to finish it off and try it out. May grab some time this weekend
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Superleggo
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PostPosted: Mon Feb 20, 2012 9:29 pm    Post subject: Reply with quote

I think I have got round the Ford Passive Anti theft System (PATS) on the ECU. It times out correctly activates the fuel pump and energises the starter motor. The PATS status is fine and it should start the engine but I have a mis match between the starter motor and flywheel combination that I have used.

My engine came from an Auto car and the flywheel from a manual. The starter motor on the Auto has a different throw to the manual so I need to swap the starter motor to a manual one to get it to engage correctly.

Then hopefully it will start. After a few weeks of disappointment I think there is light at the end of the tunnel.

Hopefully my next post will be of it running. Fingers crossed!!
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jp
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Joined: 09 Nov 2005
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Location: Chippenham, Wiltshire

PostPosted: Mon Feb 20, 2012 10:52 pm    Post subject: Reply with quote

Sounds pretty promising mate fingers crossed it's all downhill from here...

eagerly awaits video Grin
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Superleggo
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PostPosted: Mon Feb 20, 2012 11:50 pm    Post subject: Reply with quote

jp

had any joy with your wiring yet?
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jp
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PostPosted: Tue Feb 21, 2012 12:10 am    Post subject: Reply with quote

Superleggo wrote:
jp

had any joy with your wiring yet?


I'm pretty sure I have it sussed just need an EGR Module but still can't for the life of me find out what or where it was in the car. Have posted the question in 3 Ford Forums and TDOCUK with no replies. I'm hoping a car will crop up in a local scrappy or be for sale locally so I can go and trace the wires. As it stands it starts on the button but idles between 900 and 1200 rpm which I think this EGR module with smooth out as it links to the TPS and EGR valve. At least now I can crack on with exhaust and pipework etc... until I find this elusive EGR module Mr Haynes talks of... oh to still have the donor. Cry
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Superleggo
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PostPosted: Tue Feb 21, 2012 5:47 pm    Post subject: Reply with quote

JP

See your email for some info
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Superleggo
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PostPosted: Fri Feb 24, 2012 10:36 pm    Post subject: Reply with quote

Had another couple of frustrating evening with the pats light flashing saying the wiring is wrong and the Zetec and me are not friends!

But Fords Anti theft system has now kissed and made up!! But the engine will not run but a helpful soul has now told me that the crank sensor housing are not the same for the auto and manual engines.

I now think this part is the reason my engine will not run on its standard ECU

A friend has just dropped off an alternative part. Fingers Crossed for the morning!
Who said 10mm made no difference

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Superleggo
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PostPosted: Sat Feb 25, 2012 7:05 pm    Post subject: Spot the difference! Reply with quote

Here are the two different CPS housings. I can't think why Ford hid the housing behind the Flywheel when you can get at the sensor from the other side.





I am so glad I did not fit the engine as it would have been an engine out job to correct this error.

But it is all back together now.
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Superleggo
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PostPosted: Sat Feb 25, 2012 7:11 pm    Post subject: Reply with quote

Had a major sucess a bit later once I had sorted out a poor fuel pump as well!

IT RUNS

Sounds ok

Judge for yourself I am off to the pub to celebrate!!!!

Grin Grin Grin Grin Grin Grin

http://www.youtube.com/watch?v=cEZoWfukGBI&feature=email
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billy739
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PostPosted: Sat Feb 25, 2012 9:47 pm    Post subject: Reply with quote

cool

just sorted my mates mondeo banger out
its a y reg modeo 2.0

i chopped the wiring so it will run away from the car - took about 3 hrs

no dash just very basic set up , all original ecu / injection and we ran a normal out of tank fuel pump for obvious reasons

it raced well all day and he brought it home (bent)

i am about to copy the wiring for another mondeo , can keep you posted.
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