Hi gents, this is abit long but hopefully its the last push to get me on the road again so please bare with me; basically as the title states i have a 2 ltr zetec which has been converted to turbo using fiesta rs turbo inlet and exhaust manifolds along with decompression plate. i have put it into my mk5 escort which started out as a 1.8 xr3i.

Im now on the tail end of the conversion and have a few niggles to sort, firstly the engine management-im using a ofab ecu and loom, the problem being the zetec loom had cam and crank sensor and the ofab loom has just the crank sensor plug so im assuming i still stick it on the crank sensor, problem being i have no spark??

other niggles include the loom has not got a temp sensor plug?? and also no plug for the idle control valve?? the zetec had the idle control plug in with the injector rail and i cant patch it over due to a completly different multi plug.

Im also at a loss with the vacuum pipes-i have two on the inlet manifold directly under the fuel rail which i have for now joined together with vac pipe, the other is under the throttle body which i have joined onth the fuel rail think its the rite place. i have the map sensor and dont no where to give it a vac from,im assuming from one of the feeds from inlet manifold, and lastly i have a amal valve plug and dont no if ill have to earth it or out to trick the ecu or something?

Any help and advice is very much apreciated i want to get it back on the road and then eventually remap it

 

The fiesta turbo loom should have the idle valve plug on the injector loom part of the engine loom.
Also the engine coolant temp sensor and air temp sensor plugs should be on this part of the loom too.

The two vac lines on the lower part of the inlet originally are joined together then go off to the breather, the others are joined to the top part of the inlet, one to the fuel rail, map sensor and one to the throttle body.

The amal valve plug doesn't need earthing.
Sounds to me like you don't have the correct RST loom or have some bits chopped off of it

 

I was thinking this, wrong or chopped loom

 

ill have to strip the loom back have a look for chopped wires and count wires etc;

as for no spark and the cam sensor and crank sensor dilemma i dont no if i need to change the sensor or something??

Forgot to mention it was running on the xr3i zetec ecu and loom etc so i no it runs , the coil pack etc is fine but it didnt no what was happening upon boost hence went onto ofab

Thanks so far tho

 

OK Guys I have dug thru the loom and sorted temp sender and idle control valve, vac pipes are now also sorted thanks to previous advice many thanks.

Still no spark Not sure about the crank sensor and the cam sensor involvement, if I have to change the crank sensor for one from a frst??? or do some crazy wireing between the cam and crank sensor ????

I have tried a different edis and also checked all connections earths etc. Pritty sure the ofab ecu doesn't need a chip key.


Any advice or ideas???? Many thanks

 

ofab does not need a cam sensor to run, are you getting a pulse from your cps?

 

stupid question but have you actually heard the ecu turn on iirc they click and is it powering the pump up?

 

crank position sensor is ok put it back onto the zetec loom etc and ran it to confirm the coil pack etc is all working still

I basically have done the old school trick of screwdriver down the ht lead hold near steel/earth and see if I have spark. Fuel pump is building pressure etc.

Im battleing with it again this weekend

 

Again sorry for late reply im away during the week, the pump builds pressure not heard the ecu click will check now, does the ecu case need to be earthed ??

 

Found the problem now I think- I have put the original zetec loom all back on to make sure the crank sensor and coil pack are all ok..

Found the plug (a13) from the ABS has a black/red trace going to plug (a12) to ECU I think which testing with a bulb comes live from ABS plug a13.

The OFAB loom plug (a5) plugs into this but the black/red trace is blanked off, the rest of the wire colours match up.

So now im thinking it probably needs this live feed to the ecu/engine loom for whatever it feeds... Had a look on the ECU plug but cant find this same colour wire so it may change somewhere....

If anyone no's where I can find a wire diagram online so I can trace what it feeds, save me buying two Haynes manuals or had the same problem and point me in the rite direction would be a godsend!

 

Still stuck! Any help or suggestions guys ???!!!

 

Start smoking and drinking!!

 

I would have ripped the car apart, got all looms and electrics out, laid em on the floor and put it all back tracing each one to source! You'll learn alot that way! But that's what I've done in the past, but I did stealth all the wires

 

Im at that stage already !

yeh I could strip both looms rite back etc but wire colours and pin numbers vary from the zetec loom and ecu to the ofab loom and ecu so apart from checking continuity theres not much else I can doo, Im probably missing something relatively simple just need a guru that's done similar conversion I guess...

 

when i had my ofab on zt i never ran the idle control and it ran spot on with it, are you trying to run the zetec crank sensor with the ofab?

if so have you tried to run the ofab crank sensor instead?

the ofab ecu needs to be earthed, best way of doing it is using a 4pin relay,
permenant 12v live feed into battery on one, ignition live to another with it switching to give power to the ecu, and the earth of the relay to the battery not the car

this is how my gotech is wired up/ same with all my old ecu's (aftermarket), you might not be completing a curcuit hence no power to ecu and no spark.

there is guides on the internet that explain who to wire/ what a 4 pin relay does to help you wire it up or if you get stuck i could get the pin outs off mine and pm over...

if you havent earthed the ecu dont expect it to work

 

I wouldn't try and mix and match feeds to ecu from the zetec loom and the ofab loom that is just a recipe for disaster!.
I would take the ofab engine loom out, sort that, make sure all the wires are in the correct places then re install it, OR get hold of another ofab loom.
The engine loom should plug to the engine ecu and everything on the engine that it needs to see / control so in theory, you should be able to fit it to any 4 pot engine for it to run!

 

The good news is I have now got a spark, the bad news is all im getting is a giant back fire boom from the exhaust lol!

So I don't no if I have to adjust timing or something electronic??

so its not running yet but still trying when I have the time to have a play, weather, misses, kids and work permitting!

Thanks for the advice and tips guys iv not given up yet !

 

Does anyone no if the fireing order is different on a fiesta rs turbo to a zetec?? im thinking the fireing order may be different so I can maybe just swap the ht leads round to compensate....still going BOOM at present

 

If you've pluged in as per the coil pack I wouldn't suggest swapping anything round. Maybe it is actually the coil pack at fault

 

Got it sorted had to move the ht leads back one on the coil pack, no idea why its different but hey it works!

Moved them forward to begin with and it ran like a dog so moved them back once round the coil pack and it runs sound,weird?!

Many thanks to all that have made suggestions and took the time to read the scenario lol

prep for paint time and shes done

 

get some pics up or do you have a build thread?