SXE10 Altezza / 3sge BEAMS help

[quibel_nz]

Hey all, long time no post but I once again have need. I have finally removed the 4age20v engine that used to sit in the engine bay of my KP61 Starlet and started the install on my new baby, a 3sge BEAMS from a 2001 Altezza, complete with 6 speed box and factory 9000rpm center mounted tach dash.



I have wired the factory ecu up and the dash panel as per a wiring diagram i found and have yet to hook up teh body ecu or the abs/skid control (if required).

I have double checked all my inputs and earths and everything seems to be right but I have a few issues.

1) The ecu wont trigger the fuel pump relay (earth supply) when turning on but it appears to do it after crank or when turning off. note: For now I have just hooked a manual wire up to earth so its on all the time for testing purposes.

2) In diagnostic mode i get error 14/15 which is the IGT from the igniter error. Not to sure how to test this but I have checked and double checked the wires run to the right place on the ecu and they do. I have checked earth and voltage so pass. They do spark a plug when the engine is cranking so i dont know why im getting the error even though ive cleared it a number of times (i unplug the ecu over night)

3) The injectors dont appear to be earthing by the ecu. therefor i get no gas and the car wont start. I have checked and double checked the wires between injectors and ecu and they are fine and the 12v is there when required. I can manually supply 12v/earth to the injector and it opens, then when i crank it wants to start but of course there is no more gas so it dies and I can hardly sit there manually doing it to keep it going. I have pluged LED's into the injector wiring and there is nothing 99% of the time but then i might get 1 flash.

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I am wondering if the lack of earth from the ecu for the fuel pump relay at turn on and run is also related to the lack of earth at the injectors while cranking and running.

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Can anyone shed any light so i can hear this puppy roar.


Q

[RomanV]

If both your injectors and coilpacks are playing up, I'd check to make sure that the earth wires for them are connected.

They are bunches of brown wires that all tie together, and normally fix underneath the intake manifold.

I've forgotten to have them earthed before, and experienced similar symptoms!

Injectors dont provide any feedback to ECU like the coilpacks do if not working, so it makes sense that you'd only be seeing coilpack error codes if this were the case.

I know you've said that you've checked this previously, but... aaahh... yeah.

In other news, freaken sweet car! Do want.

[nz_climber]

1: This is how the system operates, so dont worry about it (well it does on mine)

2: Not sure never looked at the codes of mine as there is no light and runs well

3: Double check all the earths. There is at least 3 different earths from the ecu that need to be connected up, also check there is continuity from the ecu earths to the block and battery. Include earths from the shielded wires too

Check the earths Roman mentioned.

Also the engine wont provide any fuel if the AFM is not connected so check that (would check CAS, TPS etc too)

[quibel_nz]

thanks guys.

The earth under the intake was only finger tight yesterday so i tightened it up but the one on the top of the head was good as gold. will tripple check my earths to ecu, engine, block, battery today and the afm just incase as that is connected by junction blocks and may have a poor connection.

Roman - another pic, same car same day, different angle
http://www.performancecar.co.nz/news-5900/wings-vs-wheels-at-ardmore-showdown/attachment/wingsvswheels-474

[nz_climber]

No worries

Just read your project thread, another option for the fuel system is to keep the fuel cell and lift pump, then create a new swirl/surge tank that fits the standard altezza fuel pump.

Then keep the one way fuel system (My theory was to keep everything as close to factory as possible to give the factory ecu the best chance of keeping everything smooth and running correctly.)

The pressure regulator is in the tank attached to the pump, the bit on the fuel rail is the pulsation damper (there to smooth out the fuel pressure) so not designed to hold pressure like in the picture you showed.

Here is my surge tank (it is mounted into the top of the top of the main tank )


[/list]

[quibel_nz]

NZ_Climber - understand about the damper, that makes more sence than it being a pressure valve as I knew the tank reciculated when it got to presure.

As the Starlet used to be a track car it only had a 25L plastic cell anyways which was why I decided this morning to just buy the altezza tank complete for now. I will just plonk it on the floor up the front for testing purposes and to get the fuel working correctly and look to change the setup once it is going. I just wanna hear it roar for now.

So is that enclosure with the pump fully sealed and independant of the main tank and you use a lifter pump to fill it, or part of the tank and used as baffle protection around the pump. i can only see 1 inlet/outlet so presume it must be the latter

[nz_climber]

Sounds good, the first engine start is always good (I did mine with only the headers sticking out the side of the car.)

The surge tank is separate and sealed from the main tank, top photo shows two right angle fittings, left hand side goes to the lift pump and low pressure filter. Right hand fitting fills the surge tank. Over flow is a section of 2-3mm copper pipe (on the back side of the surge tank) Fuel from the High pressure intank pump comes from the standard fitting on the pump itself

This picture might explain it a bit better


I used this set up as I standard pump was too short to reach the bottom of the tank, also kept everything nice and compact and tidy (since space is very limited in a lotus 7) Surge tank contains 2L of fuel with the pump fitted.

[quibel_nz]

not a bad idea looks like it would work a treat. are you worried that the lifter wont fill the surge enough?

regardless ... i dunno what I did today but i have 3 words ...
"woop woop woop" , or if you prefer "It f**kin lives"

all i did was to check every wire I could then I changed the fuel setup back to factory. I went and got a complete tank from car spares, hooked it up at the front of the car, reinstalled the damper valve and hooked up the wiring. First time I cranked it after changing the tank/pump etc it started to go. now everytime i hit the ignition the car cranks over and runs via the fuel pump relay like its meant to.

Im guessing my old pump doesnt handle 60psi or something because i didnt change a wire or unplug anythign and now it goes.

who cares... its alive and i have video to proove it.



Q

[quibel_nz]

video uploaded. missed the crank cause i didnt xpect it to fire up. now it starts first pop everytime (touch wood)

http://www.youtube.com/watch?v=wDCGvgurUMA

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next issue .. does anyone know where the wire for the oil level sensor runs to i cant locate it anywhere and would love to hook that up at the same time as the fuel gauge (which is tomorrows job) now i have the tank, both senders, the body ecu and the wiring i need.

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[Bling]

That's going to be loooooose

[nz_climber]

Nice good work on getting it going!

Will send you a PM with some more details (including wiring for the oil sender etc)

[quibel_nz]

thanks climber .. the main ecu is a lot tidier than what i drew up but basically the same thing. Once I finalise mine i plan to pop em up on my personal site for all to referance to. yours have filled in a few holes in regards to the body ecu but miss a few things like doors (strangly enough :p)

looks like tomorrow is going to be busy seting up the body ecu etc.

shot all

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[quibel_nz]

Dont suppose that anyone knows what pins on the body ecu the fuel senders are meant to connect to. All the diagrams I have show pin B13 (FE) and pin B14 (FR) of the body ecu.

however my wiring loom doesnt have anything going to these pins and the PCD has differnet descriptions on them that I cant match up.

Q

[quibel_nz]

sorted ...

Thanks everyone , especially climber for you help and sugestions.

Q