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Feb 25, 2018 18:04:20 GMT
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Well, I ran out of time.
Took some time to go out with the fam this morning, Billy's on the road for some brunch. Was tasty, but ate up half the day.
Once back Mich pushed for me to go out and see if we could get it started.
It was a battle to do things properly, rather than the very real temptation to bodge things so I could try and start it.
I fitted up the water manifold with new gaskets, hoses and clips but ran out of CT clamps for one hose. That meant that we couldn't fill with water, so no extended running.
Ok, so I gapped the plugs and fitted them. Then the coils and powers / ground lines.
Finished up the exhaust by tapping a couple of clearance dimples where it was close to the transfer case. Put in the get sensors and nipped them up. So the exhaust was done.
Next up, I put 10L of fuel in the tank, only to find that my level sensor is not making sense. I am seeing either full or empty, not right.
On the bright side, the fuel pressure sensor is working as it pumps up to pressure and there were no leaks!
So, spark done, fuel done, time for a crank. Annnnnnd no bang. I think I need to investigate the ignition and triggers, because it doesn't feel like it has sparks.
By this point it was 3:30 and I really needed to spend the later afternoon with the kids. Tomorrow the weekday routine is back on, 4am leave for work, back on Thursday night.
I'll have another go next weekend, do a little bit of a deep dive on the triggers and check things over, see if we have sparks too.
Thanks guys, give me a bit more time and I promise we will start it.
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bstardchild
Club Retro Rides Member
Posts: 14,971
Club RR Member Number: 71
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Feb 25, 2018 22:18:17 GMT
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Just go thro it logically and you'll get there
I remember when I threw a 24V engine in my monza and I was faced with a cut and shut loom and nothing made sense I wondered if I was ever gonna get the curse word thing to run.......
It took help from a good friend to get it fired up cos I'm useless with electrickery
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Thanks Mr Child, I just need a bit more time, and it will be running. The nice thing is that we have really steady fuel pressure and no leaks, I was worried about that, as the system design was untested and incorporates a number of home made parts  I need to play guess who on the combustion system now, "Has it got spark? Has it got fuel? It's gotta be the (insert item not working here)" I'll keep you up to speed as and when. J |
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mylittletony
Posted a lot
Posts: 2,420
Club RR Member Number: 84
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Feb 26, 2018 15:50:07 GMT
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Keep on keepin' on, so close now! The bangs will drive you on to get it finished, can't believe you were going to (/foolishly considering) sell...
Watching with interest
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Davenger
Club Retro Rides Member
It's only metal
Posts: 7,272
Club RR Member Number: 140
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Feb 26, 2018 22:28:24 GMT
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You'll get it sussed out dude.
You're like a car jedi.
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bstardchild
Club Retro Rides Member
Posts: 14,971
Club RR Member Number: 71
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Feb 26, 2018 22:39:28 GMT
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Thanks Mr Child, I just need a bit more time, and it will be running. The nice thing is that we have really steady fuel pressure and no leaks, I was worried about that, as the system design was untested and incorporates a number of home made parts I need to play guess who on the combustion system now, "Has it got spark? Has it got fuel? It's gotta be the (insert item not working here)" I'll keep you up to speed as and when. J The logical way Slightly off Topic but a work colleague has been having a regular issue with his modern car - loses all power and dies - its then 50/50 on if it's going to re-start or not - been to main dealer three or four times - RAC called out a few times too and they've all been unable to diagnose the fault - nothing comes up on fault history and last suggestions from main dealer was replacing ECU or possibly fuel pump. He asked me for advice and based on his description of the fault said it's either fuel or spark going awol so start with the simple cheap stuff stick a new fuel pump relay and or ignition relay in it He did and the fault hasn't returned and he says it's much more responsive since £20 part - I cut the old one up to look at the contacts and they were very badly pitted and carbon covered IMO not many dealers diagnostic equipment will find faults like that and why it's important to understand how the stuff works in the first place |
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Thanks Tony and Dave, I will keep at it. There is no reason (barring broken components) that this weekend we won't have noise, even prolonged as the cooling system will be sealed up  Ian, that is a great example of plugging in to show there is nothing wrong! The diagnostics just won't show a fault like that, as they look at things like fuel pressure etc, the logic will be: 'is my pump running? No. Fuel pressure zero. OK!' Not very helpful I think my biggest issue will be getting spark at the right time, as I need to put in the offsets for the trigger wheel and pick up. I think I have an idea on it, but I need to apply the numbers and get the timing light out |
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Hi you lot! I didn't manage to spend a huge amount of time in the garage this weekend, but it was enough This week I have been tinkering with my base 'desktop' calibration, these are the base settings used to get everything in place prior to starting the engine. It also gives a good start point to do the initial running. The throttle position voltages were a bit out, meaning that 0% pedal was coming up at 8% at the ECU, this meant that the idle controller went mental as soon as it was switched on, flapping the DBW throttle about with abandon. I corrected this using the min/max voltage settings, raising the minimum to 0.55v solving the issue. Also, when cranking with compression, the main trigger signal was noisy, leaving the pick up unable to see the missing teeth and therefore TDC. The software has a built in filter for the main trigger, I turned this up a bit and the signal came back clean and clear. Now the main issue was the I spent AGES trying to get it to fire, loads of checking things, cranking but to no avail. The first thing I realised yesterday was that I had not actually pushed home the injector connectors, I thought 'here we go! This will be it!!'.....nope Ok, so I checked the fuses, all good. 12v at the injectors? yep. I literally went over EVERYTHING, and found nothing out of place. I quit early on and spend some time with the family, having a think and a google. Looking at the program later that afternoon, I clicked on the output assignment tab, and realised that the injectors had not been assigned channels. So although logging pulse width etc, there was actually no signal being sent! So I just needed to give them a channel, easy. Well could I find the injector output page? Could I fu*k! Finally, after some bedtime reading I came to a revelation. I got up, grabbed the lap top and pushed some buttons. It turns out that the injectors cannot be plainly assigned a channel, to give them an output you have to use the injector phasing tab, to associate them with an ignition output! This is the first 'quirk' of the ECUmaster software that I have come across, so far it has been crystal clear in it's function. So today, I held back, put together the cooling system correctly, checked everything over, filled it with a 50/50 mix (not taking any chances after this weeks temperatures!!). Got in and cranked it, and cranked it some more, and some more, nada. Nothing. Zilch. I took a look in the engine bay and realised that in checking the 12v to injectors yesterday, I had not re-connected the injector loom Plugged that in and BOOM, NOISE! It ran so well! Idle is a little high which will need investigation. One small coolant leak from a loose clip. One small oil leak from an o-ring that was displaced. It is also dog rich So, I have mild CO poisoning, but a working engine. Time to crack on with MOT items next Thanks you lot for all the kind words and encouragement, it helps so much to keep the momentum. More next weekend J |
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ZXRob
Europe
Posts: 1,200 
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Awesome! I have been following this thread from the very beginning and I was just genuinely happy to hear this BEAMS engine run and as you said yourself in the video it runs like factory (until the fun pedal was pressed!) Well in man! Bet you are delighted!
Rob
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sounds excellent. well done!
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bstardchild
Club Retro Rides Member
Posts: 14,971
Club RR Member Number: 71
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woot
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Fantastic. I love the , bloody hell this has actually worked , surprise.
You know that it should work yet it’s still amazing when it actually does. Well done. Brilliant.
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Thanks you guys Huge step, but still so much do to. List is now looking like this: Electrical Cooling fan, ECU controlled relay. Charge cooler fans, ECU controlled relay Charge cooler pump, direct ECU control Water injection pump, ECU controlled relay Wire in thermocouple box Wire in knock sensor Wire in VSS Wire in Logger Wire in heated windscreen system (switch and timer already sorted) Mount brake light switch Install indicator lights for fog, main beam, indicators Rear number plate lights Re-wire fuel level sensor Screen wash pump Wire in power steering pump system Mechanical Fill and bleed brakes Tighten front hub nuts (using bled brakes!) Build up clutch line Fill and bleed clutch Install and fill charge cooler system (needs one more mount) Make up vacuum manifold to distribute vac. Install boost / vacuum lines for wastegate, MAC valve, ECU, FPR Mount radiator fan Mount CC rad fan Install water injection system Weld up charge cooler pipes Install screen wash tank / lines Remove all current head lamp lenses Mould headlamp covers in carbon Mount HID projector units in outer headlamp shells Install headlamp covers Mount, seal and fill power steering pump Install seatbelts Reinforce front support bar Mount wings Mount bumper Try and drive it |
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Getting there!! Keep the faith! Cant wait to see a vid of it running!!
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Love the build thread mate huge Toyota and Gt-four fan, had my own running 403whp years back and miss it loads. Looking forward to more updates
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Lightning update guys, been mega busy with the car trying to make sure we stay vaguely on schedule. The rest of the time taken up by family, so no time for typing / photos/ videos. List is now looking like this: Electrical Cooling fan, ECU controlled relay. Charge cooler fans, ECU controlled relay Charge cooler pump, direct ECU control Water injection pump, ECU controlled relay Wire in knock sensorWire in VSSMount brake light switchRe-wire fuel level sensorScreen wash pumpWire in power steering pump systemMechanical Fill and bleed brakes(Still got a soft pedal??) Build up clutch lineFill and bleed clutchMake up vacuum manifold to distribute vac. Install boost / vacuum lines for wastegate, MAC valve, ECU, FPRMount radiator fanMount CC rad fanInstall water injection system(Injector needs fitting) Weld up charge cooler pipesInstall screen wash tank / linesRemove all current head lamp lensesMount HID projector units in outer headlamp shellsNew items on the list / remaining items: Wire in second relay box for CC pump, WI pump, CC fans, Rad fan, heated screen. Install WI tank Install WI injector (drill CC plenum, riv nut and grommet) Fill gearbox with oil New o-ring for inlet cam sensor Finish exhaust heat shield Power feed and control wires for screen wash tank / pump Wire in fuse and dedicated relay for PS pump Wire in 300a breaker in main battery feed Work out why I have a soft brake pedal? New pins / crimp tool for logger? Wire in thermocouple logger Final fit on charge cooler, fill system and bleed Check grease and re-strap rear CV boots Rear number plate lights Tighten front hub nuts (using bled brakes!) Install and fill charge cooler system (needs one more mount) Mould headlamp covers in carbon Install headlamp covers Mount, seal and fill power steering pump Install seatbelts Reinforce front support bar Mount wings Mount bumper Try and drive it Some pictures showing a bit of progress Nice OE washer tank, makes for a tidy solution. I have stripped, cleaned, and re-wrapped the wiring. This will go to a relay for activation via the stalks.  2018-03-24_05-24-36 by james hill, on Flickr  2018-03-24_05-24-55 by james hill, on Flickr Fans are in and wired, with this the front end wiring was basically there, so I wrapped it in tessa tape. Tidy  2018-03-24_05-25-33 by james hill, on Flickr  2018-03-24_05-25-18 by james hill, on Flickr Vac manifold made from some scrap ally barstock. Feeding the wastegate / FPR / MAC bleed valve / ECU / WI valve using nylon push fit lines, again super tidy.  2018-03-24_05-28-06 by james hill, on Flickr WI system, all plumbed in. The stock valve needed modification so that I would ensure secure line fitting, lots more push fit and nylon I need to decide on where to get the water from, I have a dedicated tank ready to fit, but it may be much easier and neater to use the stock windscreen washer tank?  2018-03-24_05-27-25 by james hill, on Flickr  2018-03-24_05-28-46 by james hill, on Flickr Engine bay as it looks now, pretty cool. Yes, the air filter is going there I need to make up a bucket for it, from carbon probably. This will seal up to the main bonnet vent so I can hoover up cool air  2018-03-24_05-26-28 by james hill, on Flickr Sorry for the rushed update. More soon |
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Last Edit: Mar 26, 2018 6:40:39 GMT by Blown_Imp
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Wilk
Part of things
Posts: 528
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Mar 26, 2018 19:16:10 GMT
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Well done that man. Truely inspirational!
Love the car, everything you've done to it and great attention to detail
Reminds me I need to pull my finger out and get my own ride sorted
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If it can be fixed with a hammer, then it must be an electrical fault
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Mar 26, 2018 19:51:17 GMT
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Thank you for the kind words, like most projects it is growing as we move along. I am trying to curb that a little so we can actually use and enjoy it!
Still undecided on the heat shield, it will need one, but this one is not really good enough. I guess it would be better to live with this one and then go back and make a new one at a later date?
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fatlad
Part of things
Posts: 65
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May 14, 2018 19:22:38 GMT
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How you getting on with this? Must be finished!?😂
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