Cheers Darrell..

Got a bit more noise out of it after sorting the crank signal,.. It's in the "Trying to start but not quite" phase. A lack of cam signal doesn't help so the injectors are probably firing random shots at the engine. Another go tomorrow

It lives again!!!...

That is all.

Ongoing problems with the ECU and not a particularly helpful relationship with the supplier, means that the ECU is going back and I'm mothballing the car for now and getting my life back. I'll pick up the thread as and and when I go back to it. Huge thanks to all that have taken an interest in this thread and apologies for the ending, maybe in the not too distant future things will be different.

Thanks again all.

:(

Ahhh  real shame that - was looking forward to some vids of it up and running!

A bit of a roller coaster ride this one.. And I hate quitting. I had the car running albeit roughly with a high idle and very weak fueling, prior to deciding to shelve the project for now. I was persuaded by a couple of southern kitcar guys to give them a shot at programming the ecu, this happened last Saturday, with no real progress only reaffirming an air leak causing the idle problems, which needed to be sorted before the ecu could be programmed.

The twin plenum was swapped for a single as the throttle action was crap and there was some leakage past thebutterflys

The valley gasket was removed and an oem gasket fitted. All mating faces were scrubbed until they were spotless.

Injectors were reseated into the manifold debris was found in one which would have caused a slight issue

The water jacket mounting holes, under the throttle body, were blocked up with some cut down bolts as the holes were open and letting in air to somewhere. The jacket was removed because of clearance issues with the rocker cover and no one seems to know what it does.

Never been happier about an Engine that now stalls at will lol.. And can be mapped properly, hopefully next Saturday I'll get some film of it running fingers crossed.

I popped into the garage this afternoon and saw it tucked away in the corner under a Lancia Delta... I Was quite surprised to see it there! (your Kit car that is, not surprised in seeing a Lancia on a 2 poster lift )

 

Glad you didnt jack it in and quit mike  

 

Cant wait to see it in action and to hear that V8 rumble! 

I'd gladly swap it for the Delta Intergrale Evo lol.. Great bit of kit, the S4 is one of my favorite group B rally cars.

Spent yesterday messing about with the mapping, a few challenges in the way , dodgy alternator tachometer not working, failed lambda sensor.. Bottom line, car is running better ticks over nicely and now ideally needs a rolling road to sort further. Megasquirt does have an option to "autotune' on the road, so will try that while awaiting a rolling road slot. Awaiting new lambdas the 'Old' new ones are not guaranteed for some reason.. Putting car back together and sorting out the niggles list, then will try driving gently using the auto tune and see what happens.

Grabbing any chance I can to get on the car. New lambdas fitted today and calibrated. Tidying wiring, sorted oil leak and alternator, chrome one back on the car for now.. Sorted the grinding noise on the steering a bracket catching on the back of the steering boss. Dash going back in this evening then ran out of time. To do.. sort out boss eyed look of the headlights, throttle cable and induction (again)

Don't want to tempt fate, hoping to be out and about at the weekend, (with mobile phone and AA membership card lol)

Parting company with the twin plenum, difficult to set up correctly, throttle action not brilliant and a bit overkill for the engine. Now on the bay and will probably fetch silly money as rare as rocking horse poop. I've thrown in a load of other parts that go with it. When I get round to rebuilding the 3.9, I might look at a carbon plenum with a jenvey body or two from ACT. At worse a bored out 72mm single plenum TB would do the job just fine.

Edited 2 August, 20169 yr by B33fy

Glad the end seems to be insite.

Sounds like a result - or at least on the way to one!

Yep, looking promising... Car back together and out round the block this afternoon, very light throttle only while the ecu "autotunes" as no acceleration enrichment at the moment, so as soon as you nail it the engine goes extremely lean. Plan is to run it about at a slow pace and see what it does. If it's anywhere near drivable then I can switch the autorune off and sort out the acceleration enrichment and a few other bits on it. Eventually get it to a rolling road for fine tuning.. then it's hammer time

Got to Hastings this evening, limped home from Goudhurst, will take a closer look tomorrow.

James and I got to the meet tonight, managed to give Chris a quick spin but car coughing and spluttering,.. best guess a fuelling issue. Scoffed my all day breakfast and departed whilst we had the chance. managed to get the car coughing and spluttering across town and onto my brothers drive. Plugged his laptop in AFR around 21 ish not good then it conked out completely. Intermittent fault with the low pressure lift pump which went terminal.. brand new 100 miles ago..hangs low at the rear of the car so probably took a hit at some point. Got a spare coming in the morning along with a another new HP pump, might as well swap them both over while the fuel lines are dry.

Rollover switch in the end, didn't,t realise it was fitted.. Tucked away under the car, bypassed and all good, just got to make good the wiring at the weekend.

1st blat tomorrow, local evening shortish one around mid Kent then to a juicer for a quick coke... maybe half a dozen of us, some images will be got.

Three of us in the end, trouble free run, a few knobs as usual out there, a couple of bikers trying to race us, but were just holding us up riding two abreast not watching where they were going,.. knobs.. Eaten by a cossie turbo 7 on a fifty foot straight lol

Definitely need more power..

Edited 10 August, 20169 yr by B33fy

Engine shot,, been losing oil pressure now down to 0 on tickover and 15psi when revving hard. Don't know what the issue is with the engine, it's one of those that is destined never to be right. Rather than continue to mess about chasing more problems, decided to bin it and put the 3.9 in. 3.9 is stripped and block is ready for rebuilding. Need to finish cleaning the heads and reassemble. New mains, camshaft and big end bearings, core plugs, oil pump, piston rings, complete new gaskets and a cyclone camshaft to give approx 26bhp over standard, which is 190bhp. With the exhaust and induction, should get a good 220bhp. Picking up parts on Thursday and cracking on.

Engine shot,, been losing oil pressure now down to 0 on tickover and 15psi when revving hard. Don't know what the issue is with the engine, it's one of those that is destined never to be right. Rather than continue to mess about chasing more problems, decided to bin it and put the 3.9 in. 3.9 is stripped and block is ready for rebuilding. Need to finish cleaning the heads and reassemble. New mains, camshaft and big end bearings, core plugs, oil pump, piston rings, complete new gaskets and a cyclone camshaft to give approx 26bhp over standard, which is 190bhp. With the exhaust and induction, should get a good 220bhp. Picking up parts on Thursday and cracking on.

 

Shame after all the effort so far but at least it sounds like you have a plan b...

Shame after all the effort so far but at least it sounds like you have a plan b...

I suppose it goes with the territory Sko, if I wasn't doing this I'd be wasting my time away getting on with my life.. The cars are a riot when they work, especially if there is a few of you out for a Sunday drive

As mentioned, the 3.5 lump is dead in the water, and is going off to pinto heaven, it has had a dubious history and looked like it threw a conrod at some stage in its life. On original inspection everything looked ok other than a few marks below one of the bores. Oil pressure has all but disappeared and rather than continue to chase problems, I’m rebuilding the 3.9 I acquired and shoving it in the hole.

 

 

I'm avoiding cheap pattern parts so a trip to Real Steel and boot full of bits later.. Clevite mains cam and big end bearings and Cloyes timing chain set amongst the parts. Also picked up a Cyclone camshaft, which is designed for the 3.9 hotwire engine, giving an extra 26bhp so a worthwhile upgrade.

 

Engine all ready for reassembly..

 

 

Hope this one works Mike, what power will this one produce?

I suppose it goes with the territory Sko, if I wasn't doing this I'd be wasting my time away getting on with my life.. The cars are a riot when they work, especially if there is a few of you out for a Sunday drive

 

Yeah I suppose so...   I'm just jealous really that you have the time and ability and kit to do it.  Something like this has been on my bucket list for as long as I remember but still not quite got there yet...

Hope this one works Mike, what power will this one produce?

Realistically around 210bhp 260lb/ft, maybe a touch more with the megasquirt and exhaust. Should be able to light the rear tyres up at will.. The current engine is way down on power and struggles to get the rear end to breakaway.

Bottom end built up, not happy with the valve timing, looks half a tooth out. I'll have another fiddle with it tomorrow.