S1 Rebuild(s)

[Dave Adams]

some pics of the rebuild process,

the top trailing arm bracket is broke......

the diff is sloping back a little (looking up) so that will need sorting.......

As you can see there isn't a lot of bracing in an S1 chassis, that will be sorted.

[Dave Adams]

snowy2........snowy? poxy phone predictive text.....

[Dave Adams]

a quick update....

you can see here some of the issues i have been having.....this little clump is the "earth" wires......all different colours.

and these are the ignition live "common" wires......

anyway since the loom was stripped of all the insulation i laid it out in the route i want.......only one connection plug needed lengthening, the throttle position sensor. most of the others needed shortening. the fuse + relay box for the engine management will sit on the scuttle next to the pedal box....

this is the Lambda, crank sensor, and coil wiring......as well as the power supply and earth wires. they will be routed under the coil pack....

the ECU is under the dash, and the PATS sensor is now wired up, i just need to decide where the ignition key will live. I also have kept the OBD plug and it is also ready to be found a home.

i have a few things to work out but the engine electrics are done.

i am producing a few drawings so that anyone thinking of doing the same will have an easier time of it.

[Jim (across the pond) Adamek]

I have been having a number of wiring issues so you drawings may help.

[Dave Adams]

Jim......have a look at this...wiring your car article

its what i wrote a few years ago......may help you.

[Jim (across the pond) Adamek]

Thanks Dave, It may help but there is no defined color coding on my wiring which really helps to create the nightmare.

[Jim (across the pond) Adamek]

I really lack the skill to rewire the old girl. What I am planning is to shorten the tangled up wires, remove all the black tape wrapping and putting in all new connectors. lol, All the wires are wrapped together in the black electrical tape.  I have started to remove the black tape wrapping. The tape has really broken down with old age so it is hell to remove. The wiring is my major problem on the old girl.

[Dave Adams]

I have designed the ecu fitting as a separate loom so that it can be fitted to any existing car with out needing a full car rewire. The ecu needs 5 relays and something like 6 - 8 fuses.
I have redesigned my wiring diagrams to make everything earth switched and on relays and that needs about a dozen relays......I think....will count them later. This will allow very small power switches to control everything.

[Dave Adams]

The issue I have is the cost...the cheapest method of relay holders and fuse box comes in at £72 without the wires.....a modular fuse/relay box works out at close to £100 plus wires....

[Paul Sheridan]

Oi ...... royalties are due if you use the Dutton Hinged Fuse Board System  ;-))))

[Dave Adams]

This is what I have so far..for the 60 pin ecu....

[Dave Adams]

Been working on my wiring diagrams. ...now in colour to aid their use..

Red = battery live. 

Green = ignition live.

Blue = ECU connection.

Brown = earth

Orange = component connection not above.

Above is the main ignition "on" relay and the cooling relay. Plus the fuse box connections. These are the ECU related items......the car will have a second fuse box for lights etc...

All of this applies to the ford focus 60 pin ecu....... (mine was a 2001 car, but the pin out is common to all the focus ecu''s apparently. 

[Dave Adams]

ECU wiring in place with its own fuse box and relay holder....there are two more relays near the battery, one for the fan and an "ignition on" relay.

so next.......i have started to fit the wiper motor and to do that i needed to be sure it would clear my heater box........so to be sure i decided to make another.

so i got some 1/4 ply and cut some 8" squares....once assembled it will be fibre glassed inside.

on its way........turns out 8" was too high so it was reduced in height to about 6"

the heat exchanger fitted.....

and a fiat Panda two speed fan fitted.....the front will be removable to let me change the matrix....if i need too.....