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moonspacmman9
Hi guys ( and maybe girls )
I've been a long time browser , but just signed up as Im in trouble :( :
And after reading a fix or two on hear I through ill try you lot :D

I will try to give as much info as poss , so please bear with me
1996 1.6 Zetec Escort daily driver no real problems

My car's MOT run's out @ the end of this month so I through ill do a few bits @ the start of the month to get a jump start for the MOT . Got some new rubber on the front corners , a bulb and a whiper blade , also did a filter and fluid change and I noticed a water leak , on further inverstigation it is .....
Yer you got it ... the water pump :(

Ordered a new w/p and a c/b kit ... cleaned up the said area as my p/s was leaking, striped her down and replaced the w/p and c/b kit after a few half days hear and there in my back garden

so the time to start her up was upon me , so turned the crank 2 full turns and double checked the timing marks ... BANG ON .. wow great feeling pleased with myself , had a cup of tea cookie and a smoke . had to check again so 2 more turns , all lined up aok :) Battery back on coolant topped up , s/p still out crancked her over for around 5 seconds , spanner on the crank and again all linded up :) Put Mr Sparky's back in and turned the key , fired up pretty much on the button :D what a wonderfull feeling :D

let her idle while I finished me tea and smoke ( cookie was nice so it got eaten very quick ) put the heater on just in case air locks , turned her off top up coolant , starts up again fine , so took a little chiled drive , come back and parked up. Couple of hours later I was offf out 4 the night , so jumped in turn the key .. nothing :( .. made tea and a plate of cookies and got next door to help me bump start it .. she jerked into life :) So my thinking was started motor , took s/m off the car and looked in a old haynes manule for a different ford and said about testing the s/m with a battery 2 jump leads ( I used two bits of house cooker wire ) did the said test and heard and sore the starter motor solenoid thing jump out with the gear that engages with the ring tooth flywheel , So I think ok its fine , so put back in and she started again :) Now I thinking it was just a loose connection on the s/m .. but then heard a high pitched nosie , pop the bonnet , smoke :eek: , quick look 2 c where it was coming from .. turn off , the smoke was coming from the s/m or solenoid .. So a trip to the local scrap yard and later fitted another s/m .. checked battery and still had a charge so time to start .. again she did , so left her running for a min or 2 then turned off waiting a min or 2 and restarted , on start up all ok then after a min or 2 I heard a high pitched nosie again :( , this time the bonnet was up looked and sore smoke coming from s/m area again , turned off.

Now bear with me on this next bit .. she bumped started again after 2 smokey s/m .. does the solenoid engage and dissengage the s/m teeth with the flywheel teeth ? cause it seems to me this is whats going on ?? its not disengaging and thats why it smokes after a whille ?? where does it get the signel to cut power to the s/m and disengage itsself ??

Do you know what that blue wire is that comes from the red power lead from the battery that goes to the plastic s/m connector and then goes into the loom where the earth cable is on the pully's side ? Does that have anything to do with the Passive Anti Theft System ?? Could there be a problem there in reguards to disengaging the s/m and thats why the s/m smoke's


I hope you are still with me lol .. I would be very gratefull if any of you with idears can post your throught's on this as I'm proper :confused:

Ill update this if I try anything else hehe

Thanks people
lublin
Hello moonspacmman9. My first thoughts are, have you trapped a wire and it's shorting out? Look at the starter motor (#2 top left diagram) I think your problem is with the gray and black wire that goes from the starter motor to #6 which is called Link (?) on a manual gearbox or starter inhibitor on an automatic. Check the wires and relay? here as this seems to be where the problem is.
moonspacmman9
Hi lublin

Thank you for your reply and idear
I will get back under and try and trace the said wire
Also is there anyway I can test the relay ?

Thanks
lublin
Yes, if you turn it over you can apply a currant 12v to the terminals that have constant currant when activated and then test to see it if makes a circuit on the other terminals, I suppose it could be making constant contact on those terminals but they normally fail the other way round i.e. no circuit when power applied to the other terminals. A rough test is if you hear it 'click' when power is applied, but it's only a roadside test, really.
moonspacmman9
replaced the wire and the relay and she now startts :D
thanks for your input Lublin
lublin
I'm glad you got it working. :)


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