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Thread: Ford Pop Zetec refit "No Spark"

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    Rolleyes Ford Pop Zetec refit "No Spark"

    I am looking at fitting a Fiesta zetec 1.25 into my 1955 ford Pop. I have bought a complete Fiesta removed the engine and loom. After removing unwanted wiring in the loom keeping the relevant fuel management and ignition wiring, turning the engine over there is no spark , there is power to the coil and the two other coil wires to the ECU are sound, the crank pick-up sensor wires to the ECU are also sound. the engine was running fine before removal, I may have been a bit scissor happy around the ECU and cut a wire not relevant directly to the Ignition but needed to make the ignition live, I'm sure I am not the first to fall foul of this, can anybody tell me how I can get my spark back from the ECU.... cheers.

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    Re: Ford Pop Zetec refit "No Spark"

    Exactly what car was this from ? was there a factory fitted or aftermarket immobiliser ? have you got a wiring diagram for the original car ?
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    Re: Ford Pop Zetec refit "No Spark"

    1995 fieta probably had a factory fit imobaliser triggered by a transponder key, if you loom/ecu was from such a car and you havnt retained the key and its reader coil etc then i doubt your ever get it going, sorry

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    Re: Ford Pop Zetec refit "No Spark"

    Thanks for the reply's the doner car is a 1996 Fiesta with a key, I didn't consider if the key had a transponder, I'll fetch the key this afternoon and see cross my fingers?

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    Re: Ford Pop Zetec refit "No Spark"

    you will also need to wire the key "pickup coil" to the ecu . then hold the key close to the coil when starting/running. sorry if thats obvious.

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    Talking Re: Ford Pop Zetec refit "No Spark"

    Many thanks for your advice.... got the key and wired the transponder receiver into the ECU eurekkka!!.... a spark good enough to kill a dog!

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    Re: Ford Pop Zetec refit "No Spark"

    Did you have to fit an alarm unit or was it direct into the ecu ?

    I had a look on Autodata for you but didn't really seem to show much for the Immobilliser.

    I have a '96 Escort which i'm going to be doing a similar thing with for my Mk1 Escort and would like to know how much i need to keep !!!

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    Re: Ford Pop Zetec refit "No Spark"

    great stuff !
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    Re: Ford Pop Zetec refit "No Spark"

    I wired the receiver directly into the ecu and taped the key to it, there may-be a short you can do on the ecu but being three wires and an earth I dare not risk it knacker the ecu The Haynes book I purchased to check the wiring was useless, hardly anything on the ecu 100+ connector block matched the one I had, and like you say the information on the immobilizer is very scetchy and "refer to main dealer" is in every sentence, I am putting the engine in a 1955 Pop and the wiring is obviously very basic. Out of the main fuse/relay box under the bonnet I have kept the power hold relay-to ignition the fuel pump relay and the rad fan relay, along with relevant fuses and removed the rest, you will be able to use the ones on the escort. Out of the main loom from the ECU that connects to the engine loom you will obviously need all of these for the engine management, (unless fitting carbs) basically the two 12 pin connectors, the exhaust lambda, coil and air filter box temp, and mass flow, connectors. Not forgetting the immobilizer pick-up wires as I did!! from the ECU to the dash. In all once the ecu loom is connected to the engine loom and powered up it looks after its self!

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    Re: Ford Pop Zetec refit "No Spark"

    Thanks.

    Even though i do diagnostics and electrics for a living i only have data and equipment for "normal" cars as such.

    I bought a running and complete 1600 zetec car purely for the loom and injection bits and intend to remove and run on the floor as you have done before fitting !!!

    Once i've seen it in the flesh out the car i'm sure it will be fine.


    So was it:
    White/Green
    Violet/Black
    Grey/Orange
    Black/Blue

    as that's all i can find to do with alarm etc into the ecu ?

    to the Ecu ?

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    Re: Ford Pop Zetec refit "No Spark"

    The only sure way to know is to trace the thin wires from the transponder receiver at the ignition to the block connector in the fuse/relay box, they may change colour and thickness!! In my case the thin Yellow/Green wire came out of the other side a thicker Purple/ Black.. and went to No 19 in the ECU connector, the Green/White turned into Violet/Orange.. and went to 53, the Violet/Orange went to White/Green.. and went to No8, the Black/Green Earth wire actually came out a Black/Green through the connector. how the hell you do diagnostics and electrics for a living!!

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    Re: Ford Pop Zetec refit "No Spark"

    Must be a different version to the data i have, i assume that you have not had to add anymore boxes ecu's ? sometimes they have a separate module, most of the time they do change colors thickness etc within the loom or connectors.

    On this age of vehicle you have to trace the actual wiring as you did, in a complete running car that just needs a repair that can be hard, but with plug in diagnostics you normally have a good idea of whats wrong i would use my diagnostics machine ( cheap £4k one !!! ) and then test for values or voltages at certain points to find bad connections or wire breaks.

    It's getting harder on newer cars but then the diagnostics and fault memory is getting better so with the right equipment it can be easier to trace !!!

    Thanks for the reply, when the weather gets better i'll start to strip my donor car, i'm actually quite looking forward to it.

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    Re: Ford Pop Zetec refit "No Spark"

    Hi, just an update on my Ford Pop project that I managed to complete about this time last year, and thanks for the advice regaining my spark.

    I had a lot of fun in it last year and it generated quite a bit of interest

    I mated the engine to a MK2 Escort 4 speed box, and it runs a treat up to 65
    I dont want to go much above 65 anyway as it gets a bit unstable as it is still on the original running gear suspension and ..................... brakes!

    Hopefully I have posted a couple of photos... not very good at this computer stuff...
    Attached Thumbnails Attached Thumbnails SDC10363.jpg‎  

    SDC10362.jpg‎  

    SDC10364.jpg‎  

    SDC10365.jpg‎  

    Ford Pop at Laneham 001.jpg‎  


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    Re: Ford Pop Zetec refit "No Spark"

    That looks great! Bet it pisses the purists off

    Top job
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    Re: Ford Pop Zetec refit "No Spark"

    Looks lovely that mate, that must catch a few people out on the road !!!!

    Think i'd seriously looking at the brake situation though

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    Re: Ford Pop Zetec refit "No Spark"

    Yes, the braking side was a bit of a concern when I was doing the conversion, but the engine is not much heavier than the original old iron one, just a bit quicker up to 65
    It has been through two MOT's since the modifications and the brakes are surprisingly good, better than some modern cars was one comment from a tester.
    You just have to drive accordingly... knowing to leave that bit extra braking space.
    The crossply tyres are more of a concern, they seem to have a mind of their own!

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    Re: Ford Pop Zetec refit "No Spark"

    Hi I like your pop and I am trying to build the same sort of thing, I hope you don't mind my asking but when you mated the zetec to the 4 speed, please can you tell me which flywheel did you use? I was told to use a Zetec 1800 flywheel but I can't understand how the starter will engage as part of the engine block is in the way. I have a 1.2 Zetec engine the same as yours I think and I am using a 5 speed type 9 box, I think you have t grind some of the fins off by the engine by the sump is that what you did? Look forward to any replies

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    Re: Ford Pop Zetec refit "No Spark"

    love that,

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    Re: Ford Pop Zetec refit "No Spark"

    hiya mate, did the gearbox simply bolt up to the engine? or did u have to have a bellhousing made/buy one? this engine is basicly the same as the 1.7 puma one and im looking at putting one into my 100e pop nice car btw

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    Re: Ford Pop Zetec refit "No Spark"

    Hi, sorry for the late reply I've not logged in lately. I used the original flywheel and starter on the zetec engine and made a "sandwich plate" that picked up the zetec engine mounting holes one side and the Escort gearbox holes through the other way, luckely the top two mounting holes matched, so made the job easier to align. I also had to grind a bit out of the gearbox bell housing to accept the starter motor bendix head, and also a small ammount off the gearbox input shaft end so it would enter the flywheel centre. I wish I had used a type 9 box now as I could do with a 5th gear, I thought it would be the other way with the Escort having 12" rims and thePop 17" but the gear ratio does make it rev a bit at 65. Hows your project going?

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    Re: Ford Pop Zetec refit "No Spark"

    Hi pop I not very good on the computer but pleas can u help me I like the engine you put in your pop I have a 1955 pop . Can u tell me how you connected the gear box to the talk tube I won't to do what you have don to my pop if you can help cheers

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    Re: Ford Pop Zetec refit "No Spark"

    can some one help ples I need some help building pop 103e hot rod looking for cheep engine gear box and rear axle. 105e rear axle or some thing like I live in Essex can pick up I was going to fit zetec and mk 2 escort box like in the pics put don't know how pop connected to the standerd pop running gear ; so will strip it all out if you can help me that would be good cheers.

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