Hi chaps..
I have fitted a cosworth brake set up to my kit car , the calipers are 2.0lt sierra. I have not fitted the cosworth loom to it and have not fitted the abs sensors . the pump is switched on by the brake light switch through the via a relay, after reading a few threads about problems with the pedal going hard and the pump over pressurising the brakes. I think this could be happening to mine so. Does any one have a wiring diagram of the brake system or one of ware the pressure sensor is and how it is wired so I can wire it up and see if this stops the problem.
Paul.

 

if you pm me an email i can send you the diagram later tonight

 

hi mate would it be possible for you to email it to me i am building a fiesta cosorth its got the standard cosworth brake setup i am trying to get them to work with out the abs is this possible? thanks a14ewn@btnternet.com

 

yes this is possible i did the same thing on a mk4 escort cosworth. All you do is remove the control unit loom and just run the power for the relays on the rest of the loom for the electrics. With the master cylinder you have to block the return which from memory is the center pipe connection.

 

i dont have a cosworth body loom on the car fiesta body loom and coworth engine loom can it still be done with that thanks for your response

 

The brake system has its own loom if you dont have this i would try and get one as you need to have the pressure switch and travel switch relayed to stop it over pressuring.
If you cant get a loom i would get a diagram and make your own relay loom.

 

i do have the loom i think there is just two wires red and black from the pump two pin plug of the main valve and a 5 pin plug of the presure switch just need o find out how they are wired up then it should be ok then

 

yes will be ok as long as the pump is relayed through the pressure switch

 

ok thanks for your help i will try and get the diagram need to get it on the road had it in garage for about 3 years

 

Hi mate
What I have done is run a wire to the pressure switch through a relay when the pressure drops it puts the pump on untill the accumulator on to of the pump is charged up again.
I tried to run the pump of the brake switch but when the pump keeps running it pushes the pedal up and makes the pedal hard.
I cant remember of hand which two pins I used on the pressure switch but can find out if you have not sorted it
Also you need the abs block or you will not be able to bleed the brakes it took me a week to find this out.
My brakes are now very light to push but very keen

 

yes mat if you could tell me what two you used that would be great

 

Ok mate I will look tomorrow

 

thanks alot mate

 

Hi mate

This is how I have wired my brakes, I have run a live one that comes on when the ignition is switched on, this is on my kit car so its up to you were you get your live from.
So as you look at the sensor there are five pins, you have a row of two and a row off three, when looking at it with the two pins on top the left hand side top pin run a wire to the relay and then run a live to the middle of the three pins, I have solderd mine on as I dont have a plug
So when I switch my ignition on the sensor senses low pressure and switches the live through the sensor and on to the relay this inturn switches the pump on. Once it pressurises the accumulator it will switch the pump of. Well it works on mine so good look
So looking at it left top pin of the two to relay and middle of three live.
I hope this helps and I hope you can understand what I have wrote, If you need any more help just give me a shout, if you need to talk to me I will give you my number.
Paul.

 

thanks alot mate

 

No probs let us know how you get on

 

hi raggey again did you not use the red or black that comes from he pump its self

 

What I did was run the red through the relay so that when the pressure switch switched it powered the relay which put the power through the relay to the pump
Paul.