Engine rebuild etc!! | Ford Escort Owners Association (FEOA)

Engine rebuild etc!!

Discussion in '2nd Gen 1991-1996 1.8L DOHC' started by signatures, Dec 20, 2018.

  1. signatures

    signatures FEOA Member

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    Well didn't want to get rid of the car yet, so i bit the bullet and we rebuilt the engine....turned out not to be too bad....but the aftermath now is worse

    my mechanic had a lousy helper and we decided to fix the heater and change out the heater core...then i check on him and he has the entire dash and most of inside gutted and made a mess

    problem no he must not have hooked something up because i have NO dash lights and the side mirrors don't work, plus he screwed up my stereo.....pain in the butt

    so is there anything i might be able to do for the dash lights without pulling the whole dash out again? let me know if you have any tips? thanks in advance, dave

    BTW, the engine does feel pretty strong now...just have to adjust the clutch grabbing too low
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  2. signatures

    signatures FEOA Member

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    Forgot to mention it's a 91 GT



  3. Joey_Twowagons

    Joey_Twowagons FEOA Member

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    Look closely under the dash with a flashlight and mirror. It sounds like he forgot to reconnect a wiring plug or two. With luck you can reattach them without disassembling the dash.

    To change the heater core you do indeed need to take a surprisingly large amount of stuff out. It's a huge job.
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  4. denisond3

    denisond3 Moderator Staff Member

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    I dont know if this is the same connector, but I found a multipin connector located above the driver's side fuse block, and behind the dashboard parts. I got it reconnected before I got the dashboard all bolted back into place. It had quite a few contacts. The connector was not black, it was some pastel color. Maybe that was to make it easier to spot.

    Yes, heater core removal (and the dash removal) is a big job; but it seems easier the 2nd time I did it, to one of my other Escorts. I sort of presume all of them will need it eventually. And yes, heater core removal involves the entire dash being out, so you can unbolt the plastic heater housing and pull it out of the car.

    When working on my Escorts, for things under the dashboard, I like to unbolt the driver's seat (four bolts taking a 14mm socket), and after disconnecting the seat belt light connection, I put the seat upside down on the passenger side of the back seat. Then I can put down a length of plywood to make a flat surface, and lie down on that - so as to look straight up with twisting my old back. My plywood chunk is about 1' x 4' I can open the back door, and just lie down.

    I wish the clutch engagement wasnt so close to the floor. I found it takes careful and possibly repeated bleeding, as well as careful adjustment of the length of the rod going that the clutch pedal pushes against/into the clutch master cyl.
  5. signatures

    signatures FEOA Member

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    Thanks, i'm working on it.. so far haven't found it but my mechanic will look this week..BTW, what thermostat is correct for me, temp? 180 or 195? or does it matter? thanks, dave
  6. signatures

    signatures FEOA Member

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    so far, i got part of the lights on, was the plug that has the roller switch that controls the brightness of the dash lights, but all that is on is the lights on the panel that has heater and ac controls above the radio...so that's halfway at least....still don't have the gauges and speedo and tach lit up yet


  7. signatures

    signatures FEOA Member

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    Also, anyone have an extra glove box for my 91EGT? or extra bolts for the top of air filter?
  8. Intuit

    Intuit FEOA Member

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    For whatever reason it's common not to have the wire harness in the back of the cluster *firmly* plugged into the back there. Besides it not being lit up, (which is not detectable during the day,) the alternator won't engage... meaning the battery eventually dies.
  9. signatures

    signatures FEOA Member

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    Thanks, i'm trying to reach up back there and check so i don't have to pull the dash off again



  10. denisond3

    denisond3 Moderator Staff Member

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    The OEM thermostat was likely 195 or 190 - but using a 180 seems to work okay when I have used them in my 2nd gens.
  11. signatures

    signatures FEOA Member

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    Well, spent a few hours at "Pick a Part", here in LA...and i remembered how hard it is to find certain parts for our cars....thousands of vehicles and not one GT, only one LX...
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  12. signatures

    signatures FEOA Member

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    Still haven't been able to fix the dash lights around the gauge cluster, my mechanic hasn't found what's wrong, but i told him they broke something when the entire dash was pulled out....
    I'm thinking should i try to just pull out the gauges and get behind them to check and also the side mirrors don't work, so is there any connection between the two...everything else works ok....any suggestions appreciated, dave
  13. denisond3

    denisond3 Moderator Staff Member

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    No suggestions, aside from buying the Electrical and Vacuum Troubleshooting Manual, the EVTM, for your year of Escort. (unlike the Service Manuals, the EVTMs definitely change for each year. It has all of the wiring diagrms in it, in schematic form. There are also pages showing component and connector locations, and diagrams for many of the connectors in the car. They cover the LX and the GT versions.
  14. Joey_Twowagons

    Joey_Twowagons FEOA Member

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    Does the EVTM cover diagnosing using Trouble Codes?
  15. denisond3

    denisond3 Moderator Staff Member

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    I dont recall having seen any mention of them.
    All of my Escorts are 2nd gens, where the diagnostic system would have been based on Ford's EEC-IV, which doesnt seem very sophisticated. I have yet to have had any problem where I bothered to read the trouble codes, nor any problem where the Check Engine Light being on or off helped at all.

    There are a good many pages of diagnosis in the 2nd gen Service Manuals, but so far I havent needed them either. These forums are much more helpful.

    I recall there was a publication that had the trouble codes for the EEC-IV vehicles, but I think it covered many Ford vehicles with that system, not just Escorts. The name of the pub had been mentioned in the feoa forums, but I remember it being at least a couple of years ago. Doing a google search turned up a list of the :OBD-1" trouble codes.

    In my case, its really neat to have multiple 2nd gen Escorts, so I can compare problems, sometimes swapping a part from car to car, to see if the problem moves with the part.

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