ASSEMBLY SECTION5

INSTRUCTIONS INSTALLATION
ELECTRICAL

5.1 fgnitioncoil and module. Side/Brakeand Indicator lamps shouldbe positionedas

Not all engineshavean associatedignitionmodule.lf required shownin figs.2b and 2c. Centresare pre-markedon each
they shouldbe fittedin the enginecompartment as shownin body.Drillout the required25 mm diameterholesusinga hole
f i g . 1 af o r a R o v e rV 8 a n d i n f i g . 1 bf o r a F o r de n g i n e . saw/tankcutter.Fit the bulb holderas shownin tio.2d.

F i g .1 a F i g .2 b . Fig.2c.

F i g .1 b .
F i g .2 d .
Pleasenotethat olderFordenginesdo not havean ignition
module,neitherdo olderAmericanengines.LaterFord Number plate lamp is fixedto the rearof the bootas shown
engineshavecomplexEFI computerswhich haveto be fitted i n f i g .2 e .
insidethe bulkhead.

5.2Lampunits.
Eachsmalllampwill requirean earthwire terminatedat a
convenientpointon the chassisand connectedto the bulb
holdersas shownin fig. 2a.

Fig.2e.

Reflectorshavea studon theirrear.Drilla smallholein the

fibreglassand 'screw'thereflectorintoit. Use glueon the stud
to preventthem workingloose.

Fig.2a.

SussexBNs gXJ
Pilgrim Cars Ltd., Unit14, MackleyEstate,SmallDole, Nr.Henfield, Tel: (0273)493860
tr-7
 ASSEMBLY
INSTRUCTIONS INSTALLATION
ELECTRICAL

Headlampunits are fittedby cuttingout a holethat is the 5.3Battery.

diameterof the backingbowl usinga jig saw as shownin figs ls fittedand securedwith a batteryclampas shownin fig. 3a
2f and 29.

Fig.3a. - Fit batteryand windscreenwasherbottle.

Fig.2'1.

5.4Windscreenwasherbottleand motor.
ls fitted as shown above

Fit a doublewasherjet to the centreof the bulkheadas shown

in fig. 4a. Attachtubingto its undersideand connectto the
motorvia the pre-drilledholesin the chassis.Wheretubing
passesthroughmetalpanelsyou mustuse grommets.

Fig.29. Removematerialas shownat 12 o'clockand 9 o'clock.

Fit the headlampbowlwith the rubbergasketnextto the body

and securewith selftappingscrewsor rivets:

Connectthe harnessintothe headlampbowl assembly.The

sealedbeam unit,side lamp and bezelare thenfitted(seefig.
2h) Fig.4a.
We cansupplynewwindscreen andwasher
washersystems
jetsof thetypeshownin fig.4b and4c.

F i g .4 b . F i g .4 c .
F i g .2 h .

PilgrimCarsLtd., Unit14, Mackley

Estate, SussexBNsgXJ
SmallDole,Nr.Henfield, Tel:(0273)493860
5B
 ASSEMBLY SECTION5
INSTRUCTIONS ELECTRICALINSTALLATION

SAFETYWARNING
lf using an old loom, ensureit is in good condition.
When fitting any loom, ensure it is securelytied at
regularintervalsso that no part of loom is able to chafe
againstmetalcomponents.Checkthat all terminations
are insulatedand that no exposedwire is visible.Where
wires pass through metalpanelsensurea grommetis
used.

5.5Wiringloomfitting.
A usedloomcanbe fittedintotheSUMO.Therewillalmost
certainlybe variouselectricalcircuitswhicharenotrequired in
a sportscar.Theseinclude theheatedrearscreenandits
relay,interior
lighting,
rearscreenwashwipeetc.Additionally
therearecircuits youmaynotwishto usee.g.cigarlighter,
reverse lampsetc.ltwillalmostcertainly requiremodification
in
termsof lengthening a fewwiresandshortening others.The
bulkyfuseboxwillalsoneedaccommodating andalterations
willprobably be requiredto theenginewiring.Someplugson
theloomwillalsoneedreplacing to fittheMiniheaterand
wipermotoretc.
We offera newloomwhichis suitable forallSUMO'swhich
useeitherFordGranada Mk1,2 or CortinaMk3,4,5 steering
columnswitchgear. Or alternativelywe offeranotherloom
whichutilises FordSierraswitchoear

Details
of howournewloomis fittedanditscircuitdiagram are
shownlaterin thissection.
Fittinga usedloomis basicly
the
same.

WiringProblems
It is verydifficult
to offertechnical
support on wiring,evenmore
difficult
whentheloomis notmanufactured by ourselves.
So if
youdecideto re-usea donorcarloomyouwillhaveto solve
anytechnical problems foryourself.
Naturally
we willhelp
wherewe can,butsuchavailable helpis verylimited.

Customers usinga FordCortinaor Granadaloommayfindour

Cortinaor Granada Sumoinstruction
manuals helpful.
They
detailsomeof theloommodifications
required.
lt shouldbe
notedhowever, thatthefuseboxcannotbe positionedin the
sameplaceas in ourCortina andGranadabasedcars
(becauseof the pedalpositions).

Customers whoarein anywaydoubtful abouttheirabilitywith

circuitsandwiringareadvisedto purchase
electrical a new
loom.Re-using an oldloomis onlyadvisableforthosewhoare
confidentthattheyhavethe abilityto overcomethe inevitable
problems.

Safety
Pleasereadthewarningprintedat thetopof thispage.
We cannotstressenoughtheimportance of ensuring
thatthe
wiringis properly
installed
andworking correctly.
Thisis
becausetheconseouences of an electrical
shortcircuitarefar
moreseverein a fibreglassbodiedcarthanon a normal
production model.

PilgrimCarsLtd., Unit'14,Mackley
Estate, SussexBNsgXJ
SmallDole,Nr.Henfield, Tel:(0273)493860
59
 ASSEMBLY PILGRIM
INSTRUCTIONS WIRINGLOOM

5.6 NewWiring Loom canbe almostanywhere. lt wouldnotbe practical

for us to
design,manufacture andstocka separatekindof loomto suit
General Application
eachenginetype.Insteadwe makeall thewiresforthe above
PILGRIM wiringloomsaredesigned for usein PILGRIM kit
functions(5 in all ) longenoughto reachanywherein the
cars,however, theymayof coursebe usedin othersimilar Whenthe loomis installedthewiresare
enginecompartment.
vehiclesprovidingthesamekindof switchgear is usedandthat withtheconnectors whichare
trimmedbackandterminated
thedimensions and layout is
of thevehicle roughlythesame
suppliedloosewiththe loom.Theinstallation instructions
as the PILGRIM SUMO,BULLDOG, or FAMILY TOURER.
detailexactlyhowthisis done.Fig.6a showsthe loose
CircuitDiagram connectors suppliedwitheachloom.
Thecircuitdiagram forthePILGRIM loomis extremelyclear
(bycomparison withthosefoundin production carworkshop
manuals).Thiswasachievedby drawingthe diagramin a way
whichreflectsthe layoutof the car.Whenfollowingthediagram
youwillseethatwirecoloursare markedin full(ratherthanthe
typicalabbreviatedcodes).Thefirstmentioned colouris the
maincablecolour, whilstthesecondmentioned colouris the
trace(orstripe)colour.
Earthing
Loomswhichare manufactured for metalbodiedcarsdo not Fig.6a.
needan earthcircuitwithinthe loom(because the bodyof the
Thealternator is situatedon the o/sof all PILGRIM
vehicleis usedinstead).ThePILGRIM loomhasa seDarate
recommended engines.TheseareFord1600,2000ccPinto,
earthcircuitwhichhasfourconnection pointsto the chassis.
Ford2300,2800cc Cologne V6,Ford2500;3000cc Essexand
Oneof theseis in thecockpitareanearthesteeringcolumn,
the RoverV8.Theloomis madeto accepta Lucastype
one is in the bootandthe othersare in the enginebayon
alternatoras fittedto mostCortina's andGranada's lf youuse
eithersideof the engine.Thiseafihcircuitmakesthe youwillhaveto changethe plug
anyothertypeof alternator
installationof the PILGRIMloomintoa fibreglass body
on the loomto suit.lf youusean enginewitha n/salternator
particularlyeasy.
youwillhaveto convertthe loomto suit.
Loom Specification
Apartfromalltheessential the PILGRIM
circuits, loom lnstallationInstructions
providesfor siderepeaterindicators,rearfog lamp,reverse
GeneralNotes
lamp,hazardwarning, delayedwindscreen wipers,electric
Disconnect Ensure
the batteryuntilafterthe loomis installed.
coolingfan,electricfuelpump,ammeter,radioandelectronic
thatthe loomis protected fromchaffingagainstanysharpor
oil pressuresensor.lf youdo notneedor wishto useanyof
roughedges.Whenwiresarepassedthroughholesyou must
theseadditionalfunctions yousimplyignorethoseterminalson
usea grommetto protectthem,thisalsoneatensthe
the loom.
We suggestthatyou leavethewiresin situin case
appearance of the installation.
youwishto usethemat a laterdate.
LoomPositioning
The loomdoesnothaveprovision gearbox
for automatic Drapelhe cockpitportionof the loomoverthe steering
ignition.Thesefunctionscan
inhibitorswitchesor for electronic column,suchthatthetwospursholdingthe specialblackFord
be addedby thecustomeras required. multiplugsstraddlethesteering column.Thesemultiplugsare
pluggedintothe rearof theswitchesas shownin fig.6b(Sumo).
Switchgear
The PILGRIMloomhasbeenmadeto plugintoFordsteering
columnmountedswitches. Theswitcheswhichareusedare
foundon mostFORDCortina'sMk3,4 or 5 andon mostseries
1 or 2 FordGranada's. Theycaneasilybe identified by their
functions. On theleftsideof thecolumnis theindicator.
headlamp beamandhootercontrolmultiswitch.On the right
sideof the columnaretwoswitches, onefor the lightsthe other
for thewindscreen wiperandwash.Thelatermayhave
provision for twospeedanddelayedwipe,if it doesnotit can
stillbe usedbutobviously the finishedcarwillnotbenefitfrom
the missingfunction(s). lf youintendto havedelayedwipe,you
will needthe specialrelayfromthedonorcar.
EngineConnections
Eachkindof engineis slightlydifferentin so far as its electrical
connections areconcerned. Thestartermotorcanbe on either
side,whilstthe sensorsfor oil pressureandwatertemperature Fig.6b.

SussexBNsgXJ
PilgrimCars, Unit14, MackleyEstate,SmallDole, Nr.Henfield, Tel:(0273)493860
bU
 PILGRIM
INSTRUCTIONS WIRINGLOOM

holder(supplied
Affixthe4 relaysintotheiraluminium withthe O rearstoplamps
loom)andattachthisbracketto a convenientpointon theo/s O reartaillamos
bulkhead,thenattachthefuseboxnextto it as shownin fig.6c O rearindicatorlamps
(Sumo). O rearfog lamp(if fitted)
O reverselamp(if fitted)
O Licenseplatelamp- thiscanbe connected fromthe pointat
the rearlcentre of bootor fromthe pointat thefrontoff-side
of the boot.Usethe mostconvenient placeandan
extension wireif necessary.
O fueltanksender(viaan extension wire)
O fuelpump(if fittedvia extension wires)
O heater
O windscreen wipermotor(5 pin plug)
O stop lamp switch
O siderepeaterindicatorlamps(if fitted)
O coil
O windscreen washermotor
O headlamo sub-harness
O frontindicators
Fig.6c.
O hooter
Drilla holethroughthe o/sfrontbulkheadlargeenoughto pass O electricfan switch(if fitted)
thefrontseclionof the loomintothe enginecompartment. O electricfan (if fitted)
Routethe loomdowntheo/s chassisrailas shownin fig.6d,
thenacrossto the n/s in thevicinityof thefrontof theengine Afterthe aboveconnectionsaremadethereshouldbe very
thenbackdownthe n/schassisrailtowardthe n/sbulkhead. fewlooseendsto tie up,thesearedealtwithin the nextfew
sections.

EngineGonnections
Thefivewireswhichconnectto the engineare made
andcoloursarelisted
Theirintendeddestinations
overlength.
below:

Brown(heavygaugewire) starter
WhiteiRed ..... staftersolenoid
Green/Blue .... watertemperature sender
White/Brown oil pressureswitch
Red/Green ..... oilpressure sender

Theoil pressuresenderwillnotnormallybe fittedto the

if youareusingan electronic
engine.lt is onlyrequired oil
Fig.6d. pressure gauge(likethe lsprounitsPILGRIM offerforsale).
Therearsectionof the loomis routeddownthe o/sof the
chassisintothe bootarea.Thetwo'bunches' of wiresshould In additionto the aboveconnections, a wire(white/black)
endup in thetwo rearcornersin thevicinityof the rearlamps. needsto be connected fromthe ignitioncoillo thedistributor.
lf a ballastresistoris employedanotherwire(white/green) is
Nowthatthe loomis in positionit is possibleto connectthe connected fromthe ignitioncoilto the startermotoras shown
majorityof itsfittingsas follows. on thecircuitdiagram.Thelengthsof wirearesuppliedloose
withtheloomas shownin fig.6a.
MainLoom Gonnections
Themainloomconnections canbe madeeasilyandwithlittle lf yourengineis equipped ignition
withanytypeof electronic
Simplylookat thefittingyouwish
chanceof erroror confusion. modulethenyouwillhaveto connectthe necessary additional
to connectandthenseekits wirefromnearbyin the loom.To wiresto theloom.
confirmyou havethecorrectwireyoushouldcheckits colour
againstthatmarkedon thebircuitdiagram. Onceall thewireshavebeenshortened (wherenecessary)
andconnected wiringwhichis
to the engineandanyadditional
we suggestworkingfromthe rear
Forthe sakeof convenience requiredby yourparticularenginetypehasbeenadded,you
of the car fonrvards. cancabletie themintothe mainloomandcoverthe exposed
wireswithloomtape.

SussexBN5gXJ
PilgrimGars, Unit14, MackleyEstate,SmallDole, Nr.Henfield, Tel:(0273)493860
61
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