new member with zetec issues

[dave36]

hi all  - new member with  a bit mercenary reason to be here!
I have fitted a 2.0ltr silvertop zetec to my Jago samuri kit car, most of the work done but looking for local knowledge with wiring it in!
its a non pats ecu and I have all the engine bay wiring and sensors, but not an idea how to connect it all up!
in an ideal world it would be nice to have a look at an installation someone has done, or talk to someone who knows where it all goes! I am in wells somerset.

[Moleman]

Hi & welcome to the club. I can't help I'm afraid but try putting a few pictures up & telling us a bit more about your kit & the history of where you are with it then you may get a better response to help you out. 

[garry h]

Hi and welcome to the club you will get plenty of help and advice from all of the members 

['The Gaffer']

Hi and a warm welcome to our club. Hope you get your problems sorted, sure to be some wiring diagrams somewhere I would have thought?

[Iancider]

Dave,

Welcome. 

The easiest way is to find a standard Ford engine harness from an appropriate car and it will easily and cheaply connect to all of your sensors on the right places and into the Ford ECU.  That will just plug into a standard form loom and you should be able to untape that and adjust it to fit your Jago reasonably well.  You don't say what its capacity is or whether you can find the donor to strip the harness and or loom. 

The colour codes on ford looms vary (a little) according to year - either way when you know the year and capacity we could match it all up.

Modding a ready made harness is easier than making your own due to the many and sometimes expensive connectors.

The ECU is easier to understand if you appreciate what it is doing.  It will need to know the position of the engine rotation - crankshaft or camshaft or both, the air temperature, the exhaust gases Lambda sensor, sometimes there is an anti-knock or pinking sensor, throttle position sensor.  The ECU will have he following outputs: Spark-coil outputs - one per spark-plug, injector drivers (one per cylinder), ECU fail warning light, other indicators depending on model.  It will need a power connection and at least one chassis earth and it may also have anti-theft connections that have to be used or wired out if you are no using an immobiliser.

Here are the sources of "silvertop" Engines:

Series 1 - Silvertop - Upto 1995 ish, found in Escorts, Fiesta Mk3, Mondeo Mk1
-These come in 1.6, 1.8 & 2.0 variants. It has DOHC 16V cast into a aluminum rocker cover.

Series 2 - Silvertop - Upto 1998 ish, found in Escorts, Mondeo Mk1/2
- Again, they come in 1.6, 1.8 & 2.0 variants, but have 16V Zetec cast into the aluminum rocker cover.

You can get the full history at Wikipedia - yes it is confusing because Ford used Zetec to describe car builds and engines and not all of the same type! but the summary above should suffice. 

http://en.wikipedia.org/wiki/Ford_Zetec_engine

If you can't crack this let me know and I might be able to help further - could visit if necessary.

Regards
Ian

[dave36]

thanks very much, engine is the DOHC variant, I have the full loom and all sensors, including the ones I don't need (I think)
I also have the correct ECU, which is non PATS.  Pinto loom is still present - I shall have to build or modify the starting/charging loom as neither are long enough for an inline zetec.

[Iancider]

Hi Dave,

That all sounds pretty hopeful.  You would be best obtaining a Mondeo Mk1 2.0L wiring diagram and it will show the colour code for connecting the ECU.  As you have the engine harness it will naturally offer the connectors to the sensors when positioned and most of them have individual sockets so hard to mix-up.  Because you are using the standard engine set-up, if all of the sensors are connected and working then the few connections to the ECU should be a small  step to success.  I would suggest you go to the trouble to use the colour code wires to make future maintenance easy and as per the Mondeo schematic.  The Pinto loom may be US colour code (similar) but I have stuck to European below as per later Fords

By convention: Brown = permanent 12V, Dk Green = 12V via the ignition switch, Black is Ground (chassis).  White based wires are sensors e.g. white/Brown stripe is oil pressure. 

Colour code: excellent reference at AES also a very good supplier for wire and accessories http://www.autoelectricsupplies.co.uk/cms/files/colour_code_for_vehicle_wiring_-_new_order_2.pdf

Regards
Ian

Ian