1.8 TD Engine Not Starting Following Engine Swap

[VanMan_Jas]

I have recently replaced the 1.8 TD engine (intercooled) in my van as the old one was knackered.

 

I used the fuel pump and solenoid from the original engine to keep PATS happy (the solenoid on the pump is coded to the key / ECU / PATS).

 

This is the third time I have replaced the engine, following the same process, with no issues on the previous attempts.

 

Hand primer pump is primed. When I turn the key to ignition, I hear the solenoid on the fuel pump clicking fast, approximately 10 times. I think this is normal.

 

When the key is turned to start the engine, nothing at all happens. No cranking, no starter motor, nothing.

 

There is one connector I cannot find a plug for, that I hope is the cause of my starting issues. It must go somewhere:

 

It comes from behind the passenger headlight and is long enough to reach to the gearbox side of the engine block.

 

It has 2 thick wires, one purple, one black:

http://i392.photobucket.com/albums/pp2/ax_jas/Escort%20Van/20121004_204122.jpg

The loom has a label on it:

 

http://i392.photobucket.com/albums/pp2/ax_jas/Escort%20Van/20121004_204148.jpg

BB

 

96AG-8C290

 

Any ideas what this plug is and where it goes to?

 

Once that is out the way I can start considering the fuel pump / PATS etc.

 

Any ideas? Can someone with a 1.8 TD check their loom for me?

[etrebus]

they look big enough to be starter solenoid wires stick a tester in the purple end and see if it lights when the ignition is in the crank position Edited October 5, 2012 by etrebus

[VanMan_Jas]

Ok, spent an hour looking at it today.

Turns out the connector is to the cooling fan. The reason I couldnt work that out initially is because I havent refitted the cooling fan. LOL. totally fogot about it.

 

So that is not the cause of my starting probem.

 

However, after a bit of work with the multimeter, and going back to basics, I think the issue is just a faulty starter motor.

I get 12v at the large wire on the starter ad when ignition is switched I also get 12v at the smaller wire that should kick the starter solenoid. However, nothing happens.

Either the starter solenoid is jammed or the whole starter is knackered.

Either way, I have a spare starter motor I will fit shortly and she will hopefully turn over.

 

If it was an immobiliser issue, I think PATS cuts out the starter motor and fuel pump but im not 100% on that.

 

More updates soon...

[DaweV6]

What's the red LED on a dash doing ? Is she happy ?

[VanMan_Jas]

What's the red LED on a dash doing ? Is she happy ?

Led goes out once ignition is turned on. Flashes when ignition off and key removed.

I guess that means shes happy?

 

Jas

[VanMan_Jas]

I have changed the starter motor and she now turns over and starts. Engine would cut out as if there was a fuel issue.

I tracked this down to the fuel primer pump that houses the fuel filter. Fitted a spare one I had in my garage and the engine now starts and runs!!

 

Just got to fit a new radiator top hose and bleed the coolant system and shes ready for a test drive.