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Hot!Paul's Mk2 RS2000 project - Now going ZETEC!

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Paul Dunstan
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2019/07/07 23:13:04 (permalink)
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Getting stuck into the wiring over the weekend and as the original harness was in reasonable condition I see no reason not to re-install it but I need to make some changes to improve reliability and to include some additional items (EFI, EPAS etc). The idea is to install a new fuse / relay box inside the car as I have removed the original fuse box from the engine bay. I will integrate the new fuse box and relays into the original harness via 2 8 pin connectors. I have incorporated 5 relays which are all controlled via the Haltech Elite 1500 ECU in an effort to remove the electrical loads from the OEM switchgear.
  • Fuel Pump - control the in tank fuel pump.
  • Ignition - everything that originally operated via the IGN switch in the ON position. Have split the output into two fused circuits as per the original layout.
  • Engine fan - obvious.
  • ECR - Injectors and Ignition control.
  • Starter - Starter motor control (can set the starter to automatically disengage when a particular engine speed is reached or prevent starter operation under predetermined parameters).
Overall there are now 15 fuses throughout the car - 10 mounted in the new fuse box, 2 headlamp (dipped and hi beam), 1 demist, 1 horn, 1 starter and a 40A circuit breaker for the EPAS unit. I have also used the OEM wiring within the new fuse box where possible to retain some relevance to the original schematics. A separate dual relay under in the engine bay will operate the headlamps and another will operate the horn. I will continue to use the original demister relay as I see no need to change it. The starter relay will use a fuse mounted on the relay as I ran out of fuses! So, hoping this resolves the issue of fuse reliability and prevent the melting of the headlamp switches .Also removed the old cluster connector and added an aftermarket item as I have many more inputs etc to run the additional features in the updated gauge cluster.
 
post edited by Paul Dunstan - 2019/07/07 23:34:29

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Paul
Paul Dunstan
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2019/08/08 23:00:48 (permalink)
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Powered up the electrics over the weekend and went without a hitch so I pulled the harnesses out and taped the original one in fabric tape and enclosed the ECU harness in a self closing nylon wrap. I made sure to keep both harnesses separate so they can be removed independently and used plugs where circuits transferred between harnesses.
The black plugs on the left are for ECU and white ones are to the fuse box. Red and yellow cables are the feeds for the main harness and EPAS. The coiled wiring at the top is for headlamps (additional relays), horn, starter motor and thermo-fan which exits through the original loom opening. The other (white tape band) goes though a new exit on the drivers side containing the engine wiring (sensors, injectors, coils, DBW and alternator) with the smaller loom feeding the DBW pedal.  Coiled at the bottom is the VSS and handbrake warning.
 
 

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Paul
escortinadriver
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2019/08/11 10:48:59 (permalink)
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Super neat as always

'If I'd asked what people had wanted, they'd have said faster horses....' Henry Ford

Paul Dunstan
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2019/08/12 20:42:31 (permalink)
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Thanks - it's quite a mission to keep it neat and praying I haven't missed anything! Once I sort my heater core (other post) I can install it all and wait for the engine to be finished (which is underway).

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Paul
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2019/08/12 22:21:12 (permalink)
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Hi Paul,
Nice job- electrics have always been my downfall.  My son put all the late model electrics of a 4 door sedan into his old ute, climate control AC etc, etc, V8 conversion and box.  Took him 6 months and fitted it all into his original dash so it looked standard.  Unbelievable stuff, Can't even imagine how he worked it all out- apparently started out with complete looms spread out on sheets of ply in his shed.
Paul Dunstan
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2019/08/14 17:09:22 (permalink)
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The Escort loom is hardly complex compared to modern cars but its easy to underestimate how many wires it takes to operate sequential injection, coil on plug ignition, DBW and all the various sensors required 😳

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Paul
Paul Dunstan
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2019/08/30 18:08:42 (permalink)
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A few pieces plated and I can now look at installing the brake hard-lines along with my firewall strut. I'm hoping this will preserve some of the rigidity to the firewall around the pedal box which was lost when the original brake booster tower was removed. Its a rose jointed rod which picks up on the pedal box mounts and joins at a bracket using the original tower fasten points.
 

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Paul
Paul Dunstan
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2019/08/30 18:18:07 (permalink)
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Beginning my custom DCOE inlet manifold for the quad throttle bodies. Found some 40mm ID thick walled alloy tube and squashed down one end which forms a shape identical to the oval ports of the Zetec. The runners will also be inclined at the same 20 deg angle as the inlet ports.  I already have the manifold flanges cut so hoping it will all fit together and TIG welded.
Sorting my clutch situation too as the Celica box never played well with the clutch ratio and travel of the Ford pedal using the cable clutch. Now going hydraulic with a Tilton hydraulic release bearing which also solves the poor clutch fork geometry.

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Paul
Paul Dunstan
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2019/09/14 20:17:21 (permalink)
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Hoping to get the head back soon from Warren Heath Performance who is doing a fantastic job by reconditioning the head, installing OS valves, new springs, retainers, cams and modifying the ports. Using a set of his custom grinds and hoping to unleash a few extra horses combined with the other intake improvements. Bottom end is all machined and ready to assemble once the head arrives.
Intake manifold is coming along and ready to trim the runners to the correct length and begin welding it all together.
 

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Paul
Paul Dunstan
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Re: Paul's Mk2 RS2000 project - Now going ZETEC! 2019/10/10 23:38:22 (permalink)
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Had a minor setback a while ago where I had the car on jack stands and the adjustable strut tops failed (Nolathane) allowing the struts to fall and contact the guards denting and damaging the paint - something else to fix once I get it all sorted 
Anyway, new strut tops installed and getting back to installing gear into the bay in readiness for engine and gearbox. The flexible braided lines didn't fit as they fouled on the shocker adjuster and generally weren't to my liking so I've gone back to my original hard / flexible arrangement which I'm happy with. Custom Xmember modified to include gussets in the base of the mounts as per my engineers request and painted. Have been using a KBS product (like POR15) to paint a lot of my chassis items as it can be brushed on but flows out giving a powder coating appearance. The only downside is it's not UV stable hence only good for items hidden (fuel tanks etc). Installing the battery in the boot and running the cable inside the cabin presented an issue of how to run it into the engine bay. Ended up installing a through panel battery post mounted on the bulkhead where I will terminate the started and alternator wiring on the engine bay side with battery connection and power take-offs on the interior side.
Wasn't happy with the tyres rubbing on the chassis when on full lock so I used 25mm HD PVC conduit to make 10mm spacers which fitover the rack shaft effectively shortening the max travel in each direction - all good now. EPAS and pedal box trial fitted and all looks good so I can remove and maybe look at some sound deadening options before re-installing properly.
post edited by Paul Dunstan - 2019/10/10 23:45:49

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Paul
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