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        General >> Problems >> Chase the faults.....
        
(Message started by: Scorpio_Dan on Jul 16^th, 2022, 10:04pm)

Title: Chase the faults.....
Post by Scorpio_Dan on Jul 16^th, 2022, 10:04pm

Hi, just a little on-going story.......

So, clunky noise from front suspension. It's been there since I had it. Changed the front drop links and ARB bushes.
Noticed the radiator had bulged at the bottom and leaking, ordered a new one - still waiting after delivery company had lost it!
Flushed engine and found cam sensor wiring and oil pressure switch had decayed. Repaired this.
While up on stands, I changed the gearbox filter and oil.
Tested the car, lost drive, erratic idle etc etc, oh and a flashing o/d light.

Wiggle tested wiring and stalled car. Ok, wiring is faulty.

Stripped intake off and removed wiring harness from the engine and transmission.
Its completely disintegrated.
I have made a new harness , well, I have separated the transmission and engine harnesses.
Transmission one fitted as of today, I have not routed this back through the Vee. Just finishing engine harness.

Fingers crossed it works when all this work is done!!!!!

Stay tuned for updates.......and I will post some pics later

Title: Re: Chase the faults.....
Post by a900one on Jul 17^th, 2022, 11:28am

Well done that man ;D I hope your efforts are justly rewarded.
ALl the best Gerald.

Title: Re: Chase the faults.....
Post by Nunnspoet on Jul 18^th, 2022, 9:47am

Yeah! Well done, please keep us informed.
Happy day
Mike N

Title: Re: Chase the faults.....
Post by Scorpio_Dan on Jul 18^th, 2022, 1:06pm

https://live.staticflickr.com/65535/52224321201_a64c348413_c.jpg

https://live.staticflickr.com/65535/52224595199_1e5250f64d_c.jpg

https://live.staticflickr.com/65535/52224341858_fce9b51704_c.jpg

https://live.staticflickr.com/65535/52224812160_bd7c4e6a90_c.jpg

Title: Re: Chase the faults.....
Post by Scorpio_Dan on Jul 22^nd, 2022, 9:27pm

Hi all. I'm happy to report that Scorpy is running again!! A frustrating end to a few weeks.

I have got very intimate with the workings of transmissions and sensors!

You can buy new pins for the two main engine bay connectors.

37488 - non-insulated male pins from The tool academy. 13 quid for 50 pins.

I used 18 gauge wire for injectors and power feeds and 20 gauge for sensors. All crimps run to main connectors for ease.

I hand-layed all the white cables and sheathed in DR25. Cables in the vee were covered in heat resistant material.

I managed to remove and refit transmission harness without lowering gearbox, a bit of a chore and tested my patience.

Repaired the crankcase breather pipes and two airleaks.

Sharper pullaway, VIS valve works now, no harsh overdrive changes.

If you would like, I can post the wiring info.

Dan

I have a more detailed pinout test info to hand too.

Title: Re: Chase the faults.....
Post by Tompion on Jul 24^th, 2022, 4:35pm

Glad you got it sorted.

Some of the sensor pins in the main connectors are gold plated and you're not supposed to mix the two types.
Hang onto the old ones, if you find over-time incorrect sensor values you may need to replace them.
Also some wires should be twisted pair but how likely interference is if not twisted I haven’t a clue.

In my notes on the 2.3 autobox C112 socket, pins 26 & 30 are gold plated, 17 & 20 are twisted pr. Don’t know offhand about the Cosworth.

Dave

Title: Re: Chase the faults.....
Post by Scorpio_Dan on Jul 24^th, 2022, 9:17pm

Thanks Tompion.
I used screened twisted pairs for cam, crank and speed sensor.
It's quite funny with the gold pins etc, with the wire quality being what it is! I'm suprised the car made 25yrs with no issues.
No-one at work has seen anything like the wiring condition on this car.

I have driven the car today after a wash, polish and leather clean. The gearchanges are very smooth and the throttle response is better. Awesome car - proper motor!

I repaired the heater controls today, now the fan motor runs as it should. I have Halfords coming to re-gas the aircon on Tuesday.

What's next???

Title: Re: Chase the faults.....
Post by cobrascim on Jan 13^th, 2023, 6:23pm

on 07/22/22 at 21:27:32, Scorpio_Dan wrote:

Hi Dan,
Well done in getting yours sorted.
I'm about to do the same as you have done with the wiring loom. Thanks for the pin type number I will get those ordered up. I'm a bit luckier in that I have a spare engine with the loom attached that I'm going to strip out to make new/recon one. I'm hoping this will resolve my cutting out issues.
John.

Title: Re: Chase the faults.....
Post by cobrascim on Jan 14^th, 2023, 11:29am

Hi Dan,
Did you order new plugs or were you able to salvage and re-use existing ones?
Could you post up wiring info if you have it?
John.

Title: Re: Chase the faults.....
Post by Scorpio_Dan on Jan 14^th, 2023, 6:23pm

Hi Cobrascim, I managed to save most of the plugs. Some are available online, Burton Power do some, ebay etc.
I re-used the main conns but used new pins. I replaced injector and cam/crank connectors. Terminals are available.
Some of the terminals are hard to remove without the proper extraction tools.
I will dig out my pinout info.
I'm in Northamptonshire, are you nearby?

Title: Re: Chase the faults.....
Post by cobrascim on Jan 14^th, 2023, 6:38pm

on 01/14/23 at 18:23:32, Scorpio_Dan wrote:

Hi Dan,
I'm up in Scotland so not that close which is a shame. I bought a kit with a load of pin removal tools - problem is knowing which to use ??? I think I'll strip the loom off and see which plugs I can get. New loom was priced at around £1600 that's if you can even get one. Thanks for all the info. Makes it a bit less daunting. May try videoing the bits and bobs and see how it comes out. Dunno yet as it all adds time onto the work. :-/

Title: Re: Chase the faults.....
Post by cobrascim on Jan 16^th, 2023, 12:54pm

Hi Dan,
I see your wiring info has disappeared was there an issue with it?
Regards. John.

Title: Re: Chase the faults.....
Post by Scorpio_Dan on Jan 16^th, 2023, 7:35pm

No issues as such. I didn't like the way it pasted up!
I will try another way...........

Title: Re: Chase the faults.....
Post by Scorpio_Dan on Jan 16^th, 2023, 7:47pm

PIN Wire Colour Destination

2 Black/Blue TRS - pin 4
4 Black VSS
5 Yellow/Green Post Cat LH
8 White/Blue VSS
10 Violet/White TRS - pin 3
13 Violet/Blue TRS - pin 2
14 Grey/Orange Post Cat LH
15 Green/White Post Cat LH
16 Yellow/Blue Post Cat RH
17 Brown/White TSS Twist with pin 36 - pin 3
19 White/Blue Post Cat RH
20 Violet/Grey Post Cat RH
25 White/Red Trans Oil Temp - pin 4
26 Violet/Blue Thu - crimp 1
27 Black/White TRS - pin 6
28 Black/White Solenoid 4 -pin 9
30 Black/Red EPS - pin 12
31 Black/Yellow Solenoid 1 - pin 16
32 Black/Blue Solenoid 2 - pin 14
33 Black/White Lockup Sol - pin 5
36 Violet/White TSS Twist with pin 17 - pin 2
37 Black/Yellow TRS pin 1
38 Black/Orange Solenoid 3 - pin 7

Title: Re: Chase the faults.....
Post by Scorpio_Dan on Jan 16^th, 2023, 7:50pm

Crimp 1 Pin 26 Colour

THU pin 1 Violet/Black
THU pin 10 Violet/Black
THU pin 11 Violet/Black
VSS Violet

Transmission Range Sensor

1 Black/Yellow 37
2 Violet/Blue 13
3 Violet/White 10
4 Black/Blue 2
5 Not Connected
6 Black/White 27
7 Brown/Yellow Splice Eng
8 Not Connected

Position Resistance Pin 6 – 7

P 3.7k – 4.6k
R 1.3k – 1.6k
N 660R – 807R
D 361R – 442R
2 190R – 237R
1 78R – 95R

Title: Re: Chase the faults.....
Post by Scorpio_Dan on Jan 16^th, 2023, 7:52pm

Transmission Connector

1 12v for Lockup Sol
2 Cam Sensor pin 35
3 Cam Sensor pin 17
4 Trans Oil Temp pin 25
5 Lockup Sol Control pin 33
6 Not Connected
7 Solenoid 3 pin 38
8 Spliced to Engine Harness
9 Solenoid 4 pin 28
10 12v for Sol 1,2,3,4
11 12v for EPC Sol
12 Control of EPC pin 30
13 Not Connected
14 Solenoid 2 pin 32
15 Not Connected
16 Solenoid 1 pin 31

Title: Re: Chase the faults.....
Post by Scorpio_Dan on Jan 16^th, 2023, 7:58pm

PIN Wire Colour

3 Black/Red Injector 6 pin 1
4 Black/Yellow Injector 2 pin 1
5 Black/Yellow Idle Valve pin 1
8 White TPS pin 2
10 White/Blue EDIS
12 Black/Green Injector 5 pin 1
14 Violet/White Air charge Temp pin 1
15 White/Red Crank Sensor pin 1
16 White/Green EDIS
19 Black/Green Temp Sensor
20 Brown/Red Crank Sensor pin 2
22 Brown/Yellow EDIS
25 Black/Green Oil Pressure Switch
26 Violet/White Cam Sensor pin 1
27 Brown/Red See Crimp 1
28 Green EDIS + Suppressor
30 Black/Orange Injector 4 pin 1
31 Brown/White Cam Sensor pin 2
32 Yellow TPS pin 1
33 White ECT – Engine Cool pin 1
36 Black/Blue Injector 3 pin 1
37 Black/White Injector 1 pin 1
38 Violet/Blue See Crimp 2

Crimp 1 PIN 27

TPS - Brown
Engine Coolant - Brown
Air Temp Brown/White
Post-Cat(White) - Brown/Blue
Post-Cat(Black) - Brown/Green
TRS pin7 - Brown/Yellow
THU pin8 - Brown/Green

Crimp 2 PIN38

Injector 1 pin 2
Injector 2 pin 2
Injector 3 pin 2
Injector 4 pin 2
Injector 5 pin 2
Injector 6 pin 2
Idle Valve Violet/Yellow

Title: Re: Chase the faults.....
Post by Scorpio_Dan on Jan 16^th, 2023, 8:07pm

As I may of stated before.
I made the two harnesses seperately and run the engine harness through the Vee as before.
The transmission harness has been routed up from the transmission and around the brake master cylinder.
The interconnection between the two (transmission solenoid commons) are made with a simple single way connector.

I used the pinouts from this site along with my own notes to complete the wiring. I cut the original transmission wiring at the vee and pulled it down. I only removed a lambda sensor and dropped the heatshield to get access to the linkages and wiring connectors, quite a big faff to get done but possible if your patient.

Title: Re: Chase the faults.....
Post by cobrascim on Jan 17^th, 2023, 2:03am

on 01/16/23 at 20:07:36, Scorpio_Dan wrote:

Fantastic Dan thanks. Lots of great info there. It does look like the best way to do it by re-routing the transmission wiring and I will probably do the same. I will post up how I get along hopefully sooner rather than later. Thanks again.
Regards.
John.