Hi guys, im new to to forum and also new to the sierra/ cossie world.. Ive recently bought a moonstone saph needing some work and im having a few issues mainly wiring gremlins.. Firstly the car drove into the garage needing the engine rebuilt.. Engine removed and sent away.. I set about trying to tidy up abit of shoddy wiring that was really bugging me.. Wires where disconnected, a few where cut with intentions of repairing quickly, anyway time went by the rebuild took ages and when gettung the engine back in im at a loss as to where i am and what is what😢 cant get any spark other than on single spark from cyl 2 plug lead as i turn ignition on?? I know thats not right.. Is the phase sensor gone or have i wired something up wrong?
Any help greatly appreciated guys

 

Got any pics of how you wired her up ?
Did you gap the phase and crank sensor right ?
Always something daft when they wont start ..... seen a few with relays playing up as they get really old now .....

 

I have a few photos of the wiring the way it is atm..
I also havent gapped anything yet.. Ive put it all together as best as i could from memory and now running into issues! Its so hard to find any useful information on these cars which is why i have joined up and turned to the guys who own and work on these cars! My main fumble is why when i turn the ignition on is there a single spark coming from cylinder 2 plug lead??

 

This is the relays under the ps floor

I think the order is correct bar the main plug lead being off

This is the coil wiring

 

Also if anyone could send me pictures of their engine bay/ wiring for comparison that would be great

 

gap the crank sensor to 0.6mm- 0.8mm it can pivot on the 2 fixings
phase sensor to 0.25mm and make sure it wired up right (red wire to the left )
set the plugs to 0.7mm

Good start point

 

Wiring can drive ya nuts ... pair of yellow relays ignition and fuel pump combo (from memorary ) green and purple abs ....
Go threw trace any rouge connections and do repairs for anything bare for a good base start point

 

if your dizzy cap is old check the pickup on the inside is there or not broken amd the contacts for the rotor and not mashed ... plugs are wired correct btw

 

Ok so pulled the engine out and stripped it apart, and of course i found two broken wires.. Phase sensor and earth for coil.. Repaired them tested and all good.. Put the loom back into the car thinking that that was it sorted.. NOPE! no change😢 bought new phase sensor, and crank still no joy!! Im getting no spark just the odd wee spark when ignition is turned on?? Can someone please send in some pics of their wiring?

 

It seems no troubleshooting has been performed here, just sensors have been replaced.

What is the voltage to the coil and ignition amplifier?

Does the fuel pump prime when you turn it over?

Martin

 

The best investment you will make is replacing the engine wiring loom. They will break your heart and cause all kinds of running issues. For 500 quid it will be worth it's weight in gold

 

I have removed the wiring loom tested every wire after repairing any bad wires/ 2 broken wires, i have went through and tested all pins on ECU and followed diag step by step from a previous page! Gapped crank and phase to 0.08.!
Fuel pump does not prime as it was leaking and i disconnected it.. New pump and filter bought and to be fitted this evening! There is 12v to coil and 12v right up to middle pin of dizzy cap.. Its just the random sparrk on ignition thats getting me??

 

Have you got power to the fuel pump? Try powering the pump up them try and start the car. Giving the pump a direct feed will eliminate the fuel pump relay and wiring.

You should have a love at the yellow fuel pump relay and I'm sure the engine ecu sends a switched live to the relay.

 

I hope this helps.

http://www.bigturbo.co.uk/main6.htm

 

You have to start with the basics . And if your new to the cosworth world then this link should be a big help . The crank pully must also be set up right and all the teeth must be good and iv all so had a cracked pull play up

http://www.bigturbo.co.uk/

 

I've just posted the same link lol.

 

What people have to realise James is the original Ford wiring loom has been on the car for around 30 years or more and will be gradually breaking down. I had an intermittent electrical fault on my 1990 2wd Saff which despite checking every thing could not be traced. Got the new engine, fuel pump and cooling fans wiring loom fitted and the problem disappeared !!! At the same time had wasted spark ignition fitted to bring everything more up to date. Can almost guarantee 100% a massive improvement once the old wiring loom is replaced.

 

two minds think alike 😂😂 you posted as I was righting 😉👍🏻

 

Defo matey.

 

coil wiring is the wrong way round green goes to the bottom, won't stop it starting but the coil will fail prematurely

Steve