My Winter Project

[antnicuk]

is that the same as Ben\'s turbo?

[Prof]

is that the same as Ben\'s turbo?

It\'s similar - his looks larger but has a smaller looking inlet on the compressor.  I think the turbo\'s are similar in performance as regards top power you can hope for - which would be around 400 at 1 Bar - fuelling and cooling not withstanding.  The main difference is probably where in the rev range that power comes in and over what spread.
 
Hybrids are a good solution for a medium power where you don\'t want to make 400+, as you can run with stock water/oil lines and manifold.

[Prof]

Well the replacement secondaries arrived yesterday - a pair of SARD 800cc injectors from RHDJapan - so will be fitting them tonight and retesting the fuel system for leaks.
 
Then tomorrow it\'s putting back the upper inlet manifold, filling the cooling system and cranking the engine to get rid of any remaining flooding.
 
The plan is then to fit new plugs and get it started.  I will post pics of the new rad, and I\'m also eliminating the AWS solenoid and replacing all the missing solenoids with power resistors so the stock ECU doesn\'t throw error codes for them.  WI nozzle is on the intercooler, I\'ll probably plumb the piping up in the engine bay - still need to make the WI controller, but the rest is then done.
 
Should be running again by Sunday
 
Many thanks to Gary at RotaryArt for getting the manifold gasket to me - I manage to break the one I\'d only just fitted getting the little water pipe of the manifold.

[antnicuk]

how much were the injectors dave?

[Prof]

how much were the injectors dave?

£109 delivered for the pair - and they come with new connector plugs just in case your old ones are fu bar. They came with top O ring and spacer, but not the bottom grommet/spacer - but I got a set from Atkins Rotary so that\'s covered anyways. The end of the injector has a spray pattern mixer cap built in, so they could be used as tertiary injectors - I might have to take that off - although it should be ok.
 
http://www.rhdjapan.com/jdm/SARD-800cc-X2-Injectors-RX-7-FC3S-13B-T-Series-5-12679
 

[antnicuk]

thanks for that,

[Prof]

Well - ever closer to getting it running again (well it is actually running - but idle isn\'t stable).
 
Got the new SARD injectors in - and checked fuel system for leaks - had one dribble from the small bit of braided hoses between the rails - to be expected as it\'s been moved around a bit of late.  Fixed that and then popped the upper manifold back on - what a chore that is - fiddly little vac hoses
 
With it all up and after a once round to check for anything missing - electrical or plumbing - I removed the EGI fuse and cranked it a bit for one last clear out - no petrol vapours.  Stuffed the EGI fuse back in and cranked it - Started within a couple of turns - but smoked like a wet bonfire.  Had a strange whistling noise and idle dropping - so shut the car off after the warmup - noise seemed to be coming from the turbo - and there is a lot of smoke from down there - not good.
 
Sunday - took the intake duct off, and the intercooler inlet hose - checked for oil - none in there.  Turned the compressor blades - seem ok - so not running dry on the bearings.  Decided to check the oil feed and drain pipes - oil drain is wet with oil residue - noticed my oil return was sitting a bit high - could it be pooling oil - need to get the drain off to have a look - this isn\'t easy to get to with the engine in the car - but possible if you have a helper (thanks Aceman - poor bloke only came round to borrow axle stands).  Replaced the gasket on that, and plumbed another bit of silicon for the oil drain - it\'s defo running down hill all the way now.
 
Started again - idle keeps dying - and that unhealthy screech is still there - go and search on the net for animal dying in engine bay and faltering idle.  Vac leak - that\'s what the man said - so sprayed some brake cleaner near the gaskets - as peeps said they can leak - nothing there - all hoses \'appear\' to be on - checked jubilee\'s were holding the intercooler pipes nice and tight - yep.  After much head scratching and cursing - I finally listened in on the offending whistle / screech - it was the small vac nipple that hides under tha BAC - I\'d fogotten to put it back on - but the vac line was sat right on top of it so from a quick look over it appeared to be on - \'kin numpty :Hammer.  Fixed that and started it again - now it\'s not screeching and it\'s holding an erratic idle.
 
So have to adjust TPS - check BAC is working properley - as it doesn\'t seem to stabilize the idle at all, and then reset the timing again - once that\'s done - reset idle and go check timing again - little job for tonight then.
 
Worryingly - the AFR gauge was reading low - but comparing injector duties on the primaries during idle and warm up, and checking these with RPM and fuel pressure - the gauge seemed to be off somewhat - after a little test run it\'s gone back round to the expected values - seems the sensor was fouled up by all that crap after the flooding - it certainly smelled plenty rich so I wasn\'t overly worried.
 
Pics of new rad install, my little resistor ladder that replaces the solenoids and a home brew earthing kit and new rad wiring will follow tonight...

[pdtaylor18]

Is there a formula to work out the size of the injectors. I will need some for mine eventually but not sure on the size required. I was pretty much going to go for 750\'s or there abouts anyway but those do seem a good buy. Did they add much on for shipping?

[Prof]

Is there a formula to work out the size of the injectors. I will need some for mine eventually but not sure on the size required. I was pretty much going to go for 750\'s or there abouts anyway but those do seem a good buy. Did they add much on for shipping?

Can\'t remember how much the shipping was - there was no duty or anything this end - so £109 all in for the pair  They do 720 or 750\'s as well I think.
 
As for working out what size you need - the fuel calculators on the net are pretty good for starters - you pop your sizes in and what duty cycle and it will tell you what HP that will make.  You can then work out what amount of air is required using the 14:1 calculation and doing the calculation for pounds (injector rates in pounds can be found on a lot of US sites) then you know what air flow your turbo needs.  I decided on 800\'s as that\'s the biggest size the emanage will automap when you do a swap (upto 50% bigger), but both primaries and secondaries are at slightly higher fuel pressure - so run more like 600\'s and 870\'s or there abouts.  Should be good for 300 at the rear\'s.
 
Anyway - here\'s the last crop of pics (getting dark - so flash shots).
 
As you can see - I\'ve got rid of the AWS solenoid as well now, the other solenoids are replaced with resistors to fool the ECU into thinking they are still there.  You can also see the new battery post wiring and the fan wiring - needed a dirty great big Maxi Blade to stop the fan taking the fuse out, and it has it\'s own relay now too.  There is also some additional earthing - which I may take further - I\'ve been measuring ground currents near sensors - shocking !
 
Still to do:
 
Water spray and injection
Water  Injection controller
Mapping
Some more Gauge work
Electronic suspension adjusters

[m1tch]

Its all so yummy

[L18M]

hows rixy getting on these days..?

[Prof]

Tis running
 
I\'ve finally got that TPS adjusted right - wasn\'t easy to do - took several goes - as it seems to be quite fussy - but it holds really steady idle, and doesn\'t hunt during warm up now.
 
I\'ve adjusted the idle to around 800-900 RPM, and set the timing - which always seems to be well off if the TPS isn\'t right.  But it is running very rich indeed.  I\'ve been out for a run in it with Mitch and datalogged it, but the readings were off as there was a boost leak on a split vac line.
 
I\'ve fixed that, and also replaced some of the jubilee clips with decent Intercooler hose clamps - and it was running quite a bit better - but still rich on the way home tonight.  Timing needs some work, and at the moment I\'m keeping it to stock boost levels (Max 8.8 psi), until I can get it properly mapped on the eManage.
 
I\'m just beginning to find out how to get all this done, as the forums don\'t have many rotary owners using the emanage - most of the experience with it is RX8 based - but there is some great info there.
 
I\'ve realised I need to split the primaries and secondaries onto 2 seperate maps on the emanage, and also do the same for leading and trailing ignition - which will let me control fuelling and timing with a great deal of accuracy.  Doing it this way, means that 1 adjustment map will do idle / and all the vacuum side of 0 psi, and 1 map will control all the boost side of 0 psi - where the secondaries come in.  For the ignition, 1 adjustment map is for the leading coils, and the having the secondaries on the other map allows split timing to be adjusted.
 
So there we go - I\'ve got a backfiring FC at the mo - which is keeping people off my back end :flamed and drinking more fuel that it should, but temps are nice and low with that big rad in there

[pdtaylor18]

Glad to hear that all things are finally coming together, I bought Bens turbo in the end and that coupled with the microtech should give some similar problems with the setup of the engine but it should be more plug and play..... hopefully.  What else do you have to do now apart from fine tuning ?

[Prof]

Glad to hear that all things are finally coming together, I bought Bens turbo in the end and that coupled with the microtech should give some similar problems with the setup of the engine but it should be more plug and play..... hopefully. What else do you have to do now apart from fine tuning ?

Water Injection and sprayer - I need to make an electronic controller for that, and put the pump in the spare tyre well at the back - the piping is already in, and the nozzle is in the intercooler, but not plumbed to anywhere (just got a bolt in it to stop boost leak).  I\'m going to use some hozelock stuff for the intercooler spray
 
I\'ve also got my braided brake lines still to fit and I\'ve got rebuild kits for the front calipers as well.
 
Then it\'s time to do the bodywork. :yes

[grinder]

thats great news dave !! - keep up the good work