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cosworth swb mk4 project....

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Re: cosworth swb mk4 project....

Postby Gavin » Mon Jul 12, 2010 7:24 pm

cheers trig, i'll take it all out and then strip out what i dont need
2007 T300 110 GLX MWB low roof with Twin side doors & blue ambition paint.

1994 2.0 EFI 80 SWB cosworth 24v work in very slow progress. Radiant Pink.
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Re: cosworth swb mk4 project....

Postby Gavin » Sun Jul 18, 2010 11:25 pm

right, ive pretty much got the loom out of the car, and its not as busy as it first looks.

heres a brief summary of what ive found...1993 BOA granada...


there are actually three seperate looms that run round the engine bay, one mainly serves the engine, one mainly serves brakes/abs system and the other smaller loom mainly serves the lights. i say mainly as there is some crossover between the systems and some other minor items fed off each of them. there are also two minor bits of wiring at the bulkhead, one of which serves the engine, but its actually part of the engine loom and loops back through the bulkhead - i'll come back to that in a mo.

before you start stripping it out its advisable to label everything up as you undo the connectors, its fairly obvious what everything is. a hand held label writer can be had off ebay for ebay for under a tenner, ive got a Brother pt-55, cost me 6 quid and i find i use it for all kinds of things

the lighting loom loops round clockwise as you look over the engine bay, from the bulkhead down the left hand side and across the front. the other two looms go anticlockwise, down the right across the front and up the left side. you only need the engine loom which is the thickest one, but its easier if you thread them all out.

once you've done that take the whole dash out, fairly simple job. on the passenger side of the engine bay is a fusebox, unbolt this with the two bolts at the front in the engine bay, take the top off, prise the cover out and undo all the multiplugs from the underside. thread these through the bulkhead into the car one by one and remove the fusebox.

inside the car above the passenger footwell, behind where the glovebox was you'll find the ECU, the abs module and a few other boxes, plus some relays, earth points and multi connectors. all the boxes relays and plugs unclip from their mounts, and the mounts unbolt from the bulkhead. remove these, undo the earth points and strip the sound proofing and you'll see where it all goes through the bulkhead. thread the minor wiring back through the bulkhead, you'll see it connects to the engine loom ahead of the ecu connector. undo the large multiplugs and you'll find the engine loom is now nearly free. two sets of wires remain, a large black/red wire that goes to a connector in the centre of the dash ( and on to the fusebox on the drivers side of the engine bay - im not sure where this goes as ive yet to take this box out) and a set of wires that go to a connector on the steering column - looks like some kind of collapsible crash sensor.

undo these and thread the bts of the engine loom inside the car out through the bulkhead, and you've got pretty much all you need.

thats as far as ive got.....

next step is to thread out all the redundant wiring from the engine loom (emissions circuits, auto box bits, aircon etc) and see about wiring it up to the van loom. not sure if i need anything else, as im working without a wiring diagram at the moment, but from what i can see the rest of the dash loom is simple stuff you find in every car, power circuits, lighting, radio etc so should splice right in. i might cut the other half of the large multiplugs off the dash loom so i can connect it up nice and neat, factory look :D

when im done i'll write a how-to, looks like ive got the makings of one already :lol:
2007 T300 110 GLX MWB low roof with Twin side doors & blue ambition paint.

1994 2.0 EFI 80 SWB cosworth 24v work in very slow progress. Radiant Pink.
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Re: cosworth swb mk4 project....

Postby Gavin » Mon Jul 19, 2010 6:13 pm

HELP! ive just been out looking at the van and comparing it to my mk5, and i think the engine MIGHT NOT FIT!!! :( :( :(

reason is the brake servo......its 100mm further over into the engine bay on the mk4 petrol than it is on my mk5 diesel :!: the mk5 di measures 380mm from the edge of the wing to the centre of the master cylinder, but on the mk4 EFi its 480mm :!: looking at the 2.9 mounts ive got the engine is going to be over to that side of the engine bay too. which ever way i measure it, it looks too tight!

cant see any reason for the servo's to be different, but they are. the expansion bottle is further over too.

can someone confirm if the 24v is known to fit in a mk4, and is it that mk4 and 5 servo position is different, or is it diesel/petrol that is different?
2007 T300 110 GLX MWB low roof with Twin side doors & blue ambition paint.

1994 2.0 EFI 80 SWB cosworth 24v work in very slow progress. Radiant Pink.
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Re: cosworth swb mk4 project....

Postby Luke » Mon Jul 19, 2010 6:17 pm

dont worry Gavin i share your pain :lol: mines exactly the same :( :lol:

to make it fit 1st i packed the servo off at an angle - then decided i wanted it strait so put it back and chopped the corner off the plenum (bad move) what my plan was, was to change the plenum for an open one but what i'm gonna do now is fit an electric abs pump (without the abs) :D

at least you can just fit mk5 stuff - way i look at it a servo's not a problem it doesnt need to be there - if it was something like a steering rack it'd be more of a problem :!: :D
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Re: cosworth swb mk4 project....

Postby Gavin » Sun Jul 25, 2010 8:04 pm

well the granny has gone, ive got space to work on the van now. :D i got £30 quid for what was left....put it up on a scrappage website and had a call back 30 mins later from a girl saying they'd be round today.....thought she was just running the phones till this skinny pretty little thing complete with greasy cheeks and a huge rack busting out her vest top knocked on the door :lol: guess her bloke must be in the truck....nope, her two younger sisters got out the cab and the three of them set about winching it on the truck and hitching an escort on the a-frame on the back.

think of megan fox in her opening scene of transformers and you'll get the idea :lol: :shock: :D
2007 T300 110 GLX MWB low roof with Twin side doors & blue ambition paint.

1994 2.0 EFI 80 SWB cosworth 24v work in very slow progress. Radiant Pink.
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Re: cosworth swb mk4 project....

Postby Gavin » Sat Jul 31, 2010 9:46 am

ok sensible post time..got the engine on its stand and in the workshop...

Image

going to fit a new waterpump, fan belt, the engine mounts and check things like plugs etc while its on the stand.


got a few questions.....

does the oil filter fit in the transit engine bay on the extension arm its on in the granada?

do i need to change the sandwich plate to run an air/oil cooler?

does the viscous fan fit in the transit engine bay or am i better running kenlowes?

does the granada steering pump work with the transit rack? the granny one has a a 2-pin plug on the bottom, any idea what its for?

where do people take the servo pipe to on the engine?

ta...
2007 T300 110 GLX MWB low roof with Twin side doors & blue ambition paint.

1994 2.0 EFI 80 SWB cosworth 24v work in very slow progress. Radiant Pink.
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Re: cosworth swb mk4 project....

Postby Luke » Sat Jul 31, 2010 9:55 am

cant help with all of these as my engine bay is slightly different but...........

got a few questions.....

does the oil filter fit in the transit engine bay on the extension arm its on in the granada?
mine i just did away with oil cooler - i was gonna fit a seperate air/oil one but i havent yet

do i need to change the sandwich plate to run an air/oil cooler?
dunno havent done it yet

does the viscous fan fit in the transit engine bay or am i better running kenlowes?
i dont think it does - wouldnt in mine anyway to i used sierra twincam fans just cos i'd got some lying about

does the granada steering pump work with the transit rack? the granny one has a a 2-pin plug on the bottom, any idea what its for?
yes it does - the plug on the btm is for variable assitance - low speed parking or something it's not connected on mine - i think its just a relif valve - not all grannys had it

where do people take the servo pipe to on the engine?
back of the plenum - i converted one of the old egr pipes

coming soon to a profile near you ...............Image :lol: :lol:
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Re: cosworth swb mk4 project....

Postby madbri » Sat Jul 31, 2010 12:32 pm

Gavin wrote:well the granny has gone, ive got space to work on the van now. :D i got £30 quid for what was left....put it up on a scrappage website and had a call back 30 mins later from a girl saying they'd be round today.....thought she was just running the phones till this skinny pretty little thing complete with greasy cheeks and a huge rack busting out her vest top knocked on the door :lol: guess her bloke must be in the truck....nope, her two younger sisters got out the cab and the three of them set about winching it on the truck and hitching an escort on the a-frame on the back.

think of megan fox in her opening scene of transformers and you'll get the idea :lol: :shock: :D

any piccys :mrgreen: or did u do 1471 for a telephone no i might just have some spares for her :mrgreen: :oops: :lol:
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Re: cosworth swb mk4 project....

Postby Gavin » Sun Sep 19, 2010 4:03 pm

making slow progress....as usual :roll: got the engine mounts off the lump and the manifolds...coo....arent the valves small :?:

have cut the trumpet out of the granny airbox so i can fit a cone filter from caprisport. going to get a fitting tigged into the egr pipe from there too, that will be the vaccuum for the servo.

Image

what's all this then, carbon fibre? LCD monitor? shhh....its a little something to rival AlanN's plastrickery.


Image


more on this soon :wink:
2007 T300 110 GLX MWB low roof with Twin side doors & blue ambition paint.

1994 2.0 EFI 80 SWB cosworth 24v work in very slow progress. Radiant Pink.
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Re: cosworth swb mk4 project....

Postby AlanN » Sun Sep 19, 2010 10:03 pm

Im watching :lol:
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Re: cosworth swb mk4 project....

Postby transitandy » Mon Sep 20, 2010 12:33 pm

good thread m8y :)
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Re: cosworth swb mk4 project....

Postby Luke » Mon Sep 20, 2010 1:06 pm

Gavin wrote: going to get a fitting tigged into the egr pipe from there too, that will be the vaccuum for the servo.

can't you use the existing pipe ? just cut it off an join it :?: you arnt keeping the egr are you :?
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Re: cosworth swb mk4 project....

Postby Gavin » Mon Sep 20, 2010 4:26 pm

Luke wrote:
Gavin wrote: going to get a fitting tigged into the egr pipe from there too, that will be the vaccuum for the servo.

can't you use the existing pipe ? just cut it off an join it :?:



i guess.... but it looks neater, little bit of bling for 15 quid :lol:
2007 T300 110 GLX MWB low roof with Twin side doors & blue ambition paint.

1994 2.0 EFI 80 SWB cosworth 24v work in very slow progress. Radiant Pink.
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Re: cosworth swb mk4 project....

Postby Gavin » Wed Sep 29, 2010 8:17 pm

right then... ive had a re-think......and i'm going to make a rash commitment. this van will be roadworthy, taxed and tested, ready for north weald 2011 :lol:

ive got someone lined up to make the manifolds, ive found a very competitively priced hire co that will hire me a self drive transporter with 1650kgs capacity so i can get it there.


all the othere ideas ive got like the dash pod, wheels, suspension, clocks etc can wait. i want to drive the thing :mrgreen:

engine is going in before christmas, manifolds will get done over the winter, wiring and mot-ing in the spring

once its running, it can evolve into what i want it to be as time allows....
2007 T300 110 GLX MWB low roof with Twin side doors & blue ambition paint.

1994 2.0 EFI 80 SWB cosworth 24v work in very slow progress. Radiant Pink.
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Re: cosworth swb mk4 project....

Postby Gavin » Fri Oct 01, 2010 10:37 pm

had a chat with a trusted mechanic (was my dads apprentice many years ago when he was in the trade :lol: ) today about the overheating problems, and my fears about the headgasket(s)

he's told me, given the way it used to overheat, that its very unlikely to be the gasket and more likely to be problems with the viscous fan, thermostat or waterpump. so thats another thing thats had me procrastinating out of the way :lol:
2007 T300 110 GLX MWB low roof with Twin side doors & blue ambition paint.

1994 2.0 EFI 80 SWB cosworth 24v work in very slow progress. Radiant Pink.
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