I have to think about the electrics. I was concerned because the donor car had an engine management processor, an ABS processor, a unit to identify failed bulbs, another which I can't remember its use and a mass of wires which alone weigh over 14kg. I discussed it with Paul from Beauford who recommended that I ditch it and buy a simple loom that they use. So I've ordered the loom from premierwiring.co.uk, he makes them to order so it will be with me by the end of August.
The wiring loom has arrived and I'm trying to work out what goes where. It appears the loom is for a car with a carburettor, not for the EEC iv engine management system with petrol injection! I suppose I could convert the engine to a standard carb set up, it would be a lot simpler, but more expense, I'll see how it goes.
I can't get hold of anyone from Premier Wiring, they're re-locating to Spain. So I've decided to extract that part of the wiring from the Sierra loom, luckily I haven't got rid of it yet. It appears to be a straight forward process with all the engine connections on the one section loom. I'll just have to work out how to link it in with the PWS loom!
I've put the engine management part of the loom in, basically the engine loom. Just need to work out how connect it to the main loom! Every day I work on the car, I spend about 30 minutes looking at the loom trying to work out how to tackle it. Should I attempt to use the Sierra loom and heavily adapt it or use the PWS loom? After 30 minutes I come to the same conclusion, I'll get on with something else it doesn't have to be done yet! The trouble is it's getting nearer to decision time.
I spent all day with the PWS loom on the dining table and labelled all the connections, so now I know where they should go. The only thing I can't work out yet is how to connect it to the ECU! It should be simple, take the wire that comes from the ignition and connect it to the engine management relay (both of them?) But, the wiring diagram does not show anything as obvious as that. It starts as one colour at the ignition changes into several different colours and goes to several different points one of which is the immobiliser (which I had no intention of fitting). I have no idea whether the connections are +ve or -ve that come from it and the same with the ECU. If I connect it the wrong way round I could blow the ECU which would be expensive!
Spent several days analysing and taking the Sierra loom apart, I've finally isolated what I need to run the engine. At least I think I've isolated it, time will tell. When I looked at the section of loom from the automatic gearbox I found the wires were all perished, the insulation was cracked and flaking off, so I needed to replace it. I rang my local Ford dealers, to get a new section. They could tell me the part number and the engineer code, but it was also not possible to get it. I did a search on the web but the only hit I got for the part number was a picture in a parts manual. I couldn't get the section of loom so I had to make one up to replace it.
I put it in the car, connected all up and got the engine to turn over. At least I know the ignition is connected to the starter. I now need to marry the PWS loom to the Sierra loom.
Spent several days putting the wiring in temporarily. I've made a hinged shelf under the passenger side dash and fitted the ECU, it also gives me access to the the fuses and relays. I connected the battery up with a 15amp fuse in the negative cable so any shorts would not burn the loom out. So it's connected but only with twisted wires and insulation tape. After connecting the fuel filler I needed to add some petrol and get the car started. But, before I could put any fuel in I had to take the filler pipe of again to take the rag out I had put in to stop any bits going into the tank. I must try and remember when I have done something sensible!
Once I had succeeded in putting the fuel in I tried to start the car. It wouldn't turn over, I was surprised because it had worked before. I checked the circuit out and found a connection I had disconnected to prevent me turning the starter accidentally (something to do with age again!!). Once connected it turned over but wouldn't start. I had forgotten to connect the fuel pump. Once connected it started first time, runs fine until I drop it in gear, when it cuts out. I must have a problem with the automatic transmission isolator or low transmission fluid.
No, it's not low transmission fluid, I've put 3ltrs in and its made no difference. I guess I'm going to have to spend some time tracing the circuits back and find out if there's a short or break anywhere!
I stripped the section of loom that went to the automatic gearbox and made sure the connections were all intact and put it back together again.
Still no difference. There was a spare connection not linked to anything, I suspected it was the reversing light, so I plugged it in. It worked! So I disconnected it and tried it again, it still worked. I'm working on the assumption it was just coincidence and the topping it up with transmission fluid was the real problem. It wasn't the reversing light or at least its not working but at least I can drive it in and out of the garage.
I've been having electrical problems, it's a voyage of discovery, every day it's different. One day it starts and works as it should, the next it will start in gear (its an automatic it shouldn't). The next when I put it into gear the engine dies. Another day putting it into gear doesn't affect it, but when I switch on the lights it kills the engine. I fitted another earth lead from the battery to the chassis, that appears to have resolved some of the issues, but the engine will still turn over in gear even though it doesn't start.
The loom wires are now where I want them so I've wrapped them in insulating tape, it's a lot tidier now. The dashboard and the centre console are now fitted . It looks like a proper car now!
To keep the cost down I'm using the Sierra speakers, they may be old, but top quality speakers would be lost on an open top tourer and they're good enough for me. The front speakers I'm putting in the front footwell and the rear speakers are going to go in a panel beneath the rear seat.