Getting the engine running,the Saga!

karism · Post by **karism** » Mon Apr 14, 2008 10:45 am

Morning Guys!
Since I bought my 200sx in a non running condition, there were some things that needed tending to.
Firstly : the starter would turn for quite a while, backfire a good couple of times trough the exhaust, and then fire up. Ran for about 1 second ,and then died.

To me, this spelled one symptom…. Ignition Timing!

Now I’m not very knowledgeable with Pistons engines at all. Although I understand it, and have modified quite a few of them, the thought of 16 valves, 4 pistons, little sticks being turned with a belt just generally scares the crap out of me.
So the help of Turbonutters was called in.

We removed the CAS, and there was a very nasty surprise for us there…

The drive in the exhaust cam, was broken off. It didn’t seem like it was the result off abuse, but rather it got worn out slowly over the years. What to do, what to do?

Decided a new pin would do the job! So we took a piece of high tensile strength shaft, and turned it on the lathe.(refer to the pics please)
We knocked the new pin in, and reinstalled the CAS. Setting the timing roughly.

Turn the key…chi-chi…VROOM!It was purring like a small Ginger colored kitten!Yeehaaa! Ride em cowboy!

Ran smoothly for a few minutes, and then it died. Oh crap. What now????

CAS came out again. The brand new machined pin, had broken off. Halo??Was the machinist drunk by any chance?(Actually, slightly intoxicated, as were the rest of us,hahaha)

The Exhaust cam pulley had some scuff marks on it, where the new pin was grinding away..

What do we do now?

I took off all of the front engine covers, radiator cowling, cam belt and various other weird things that 4 cylinders use! I was making sure that the broken off pin wont cause poo-pee. We found it at them bottom of the crank pulley. Thank goodness!

What to do now?

Installed everything back where it was supposed to go. Took off the exhaust cam pulley, and made a slot in it. The little slot will provide a space for the pin to fit into, and not break off again!

Arrrghhh! We be clever after beer!

Fitted everything in, and it was once again running like a ginger colored kitten!The test drive followed

Part 2 Will follow shortly!

karism · Post by **karism** » Mon Apr 14, 2008 10:53 am

karism · Post by **karism** » Mon Apr 14, 2008 10:54 am

ChemCool · Post by **ChemCool** » Mon Apr 14, 2008 2:00 pm

So the help of Turbonutters was called in.

Very nice guys these Turbonutters. Gerhard and Andre. They are the people who sponsor Gremlin(George).

www.kwikwap.co.za/gremlin

looking forward to the "to be continued"

Chem

karism · Post by **karism** » Mon Apr 14, 2008 2:49 pm

Part 2
The Sx was running fine with the CAS working like it should. It started on demand, and drove well.
My brother came to look at my new toy , and take it for a spin. (Does feel weird sitting shot gun in your own car, doesn’t it?)During the spin, he looked at me, and said that the engine is pining!

I was worried, real worried. We all know pining lead to knock, and knocking leads to conrods, valves and other bits coming outside for a little ”visit!”

I retarded the timing, and the pining went away. It was less pleasant to drive now. ..It didn’t want to spool so quickly anymore, and the thrust was much less fierce. I was disappointed, real disappointed.

On Sat we put buttcrack racer (My lovely Sx) on the CO machine. The specs said the Co level should be 2.0 max. It was running 0.2 !!!! How in hells name was it even starting up with a mixture that lean?
We tried adjusting it on the AFM for a few minutes, but it made no difference.
We then directed out attention to the fuel rail. I know some of the Sx`s had the knack of loosening their own injector plugs while driving. Butt was doing fine, all of the injector plugs were nice and snug.

Next we decided to have a look at the Fuel filter. Removed and had a suck through it. * Mental note :Next time try blowing, fuel does not in end up in lungs that way*

It was flowing fine, no obstruction.

Next up?

We took the fuel supply pipe off, and added a pressure gauge to it.Any proper EFI pump should push in the region of 5-6 bar when unregulated, and pushing directly into the gauge. I was getting a reading of 30PSI ,which is about 2.2 bar. Arrrggghh! We be found the problem! hahaha

We headed to Autozone, and bought a nice universal pump. It was made by Bosch and fitted easily with some small mods.
(I was trying to get AWAY from the German products, but Murphy is always around)
I fitted the new pump… ARrrrghhh !!! It be purring like a kitten!

Took it for a little spin(haha, no pun intended) around the block.

Holy Cow! What a difference! It goes like the clappers now! Doesn’t ping/knock/break, and the Co is where it is supposed to be!

My little Buttcrack racer is healthy, idle is stable, and does not show any signs off general unhappiness.

A VERY ecstatic 200Sx owner!

Yip, the guys at Turbonutters are great. I have known them for many years now.

Toby · Post by **Toby** » Mon Apr 14, 2008 8:08 pm

hehe nice write up! Thanks, I enjoyed reading through that

veecee · Post by **veecee** » Mon Apr 14, 2008 8:19 pm

ya it was a great story, but i see a few concerning flaws...

1. its pinging - and it doesnt lead to knocking, it IS knocking. just another word for it. probably came about because pinging tends to sound like ball bearings being rattled around in a glass jar!

2. CO testing these days requires some pretty fancy equipment. the old CO testing equipment doesnt work because petrol doesnt have lead in it anymore! so getting a low CO reading like that is possible. i wouldnt trust a test like that unless its a modern testing machine!

3. does your exhaust gas smell like petrol??? is your engine standard??? does your management system know that you're running too much fuel pressure?
LOL - the FSM for the ca18det says that feul pressure should be at 36PSI - so your stock pump wasn't far off.

karism · Post by **karism** » Tue Apr 15, 2008 8:31 am

I`am glad you guys enjoyed reading it!

veecee wrote:ya it was a great story, but i see a few concerning flaws...

1. its pinging - and it doesnt lead to knocking, it IS knocking. just another word for it. probably came about because pinging tends to sound like ball bearings being rattled around in a glass jar!

2. CO testing these days requires some pretty fancy equipment. the old CO testing equipment doesnt work because petrol doesnt have lead in it anymore! so getting a low CO reading like that is possible. i wouldnt trust a test like that unless its a modern testing machine!

3. does your exhaust gas smell like petrol??? is your engine standard??? does your management system know that you're running too much fuel pressure?
LOL - the FSM for the ca18det says that feul pressure should be at 36PSI - so your stock pump wasn't far off.

Ok, here we go

1. As stated, I have never before heard pinging (knocking) before, as imam new to the whole piston engine diagnostics thing. The last time I was around mixtures on Piston engines, was when the Vw`s were still running Bosch K-jet mechanical injection! So, if the term I used was incorrect, sorry, it’s for lack of a better description! (Damnit! All these stupid different names for the same thing, hahaha)

2.The Co tester used was not a home made machine believe me it is a professional machine ,Turbonutters is a Pro Workshop and do not use dodgy machines! Allso note that the stock fuel pressure on a 200sx according to the manual is about 36PSI like you said. The difference is: Its the job of the FPR to regulate the pressure. The fuel pump should be able to push more than 2 bar when it isnt being regulated by the FPR. See what I mean? Also, if it was NOT the pump, then why couldn’t we adjust the CO level? Nothing else was changed.

3.No my exhaust does not smell like petrol, and it doesnt blow black(petrol)smoke when boosting, or even off boosting.My engine is 100% standard, with the exception of a 63mm exhaust. I`am running the idle control valve, warm up valve and all of the stock other fueling bits. I`am even running a stock airbox!

My knowledge on Piston engines isnt the best,but i have spent many months of my life tuning fuel and ignition on other engines.

It is running like a champ now with the new pump fitted.

Daniel · Post by **Daniel** » Tue Apr 15, 2008 9:09 am

Great stuff, glad you got it sorted.
I also had a problem on my CAS where the pin kept falling out. happend many times. eventually fixed it by forcing in a piece of allen key that was alittle to big actually. Broke the hydrolic press and then i just moved onto a BIG hammer. never came out again

A mate of mine will be very interested in your beetle project. He wanted to do a rotary conversion on his...but he's somehow changed his mind and is busy installing a 1.5L nissan engine

THEO 3K - ZN · Post by **THEO 3K - ZN** » Tue Apr 15, 2008 9:37 pm

Wats the cause of black smoke wen boosting?

veecee · Post by **veecee** » Wed Apr 16, 2008 7:40 am

@karism - all the things you say make sense, and i didnt intend to start an argument. i also didnt say the guys weren't PRO, i'm just saying that the machines that were used before leaded petrol was phased out, wont be able to measure CO's properly.

also - i didnt read the part about the unregulated fuel pressure properly. my apologies.

but you should set your fuel pressure to what is says in the manual, specially if your car is stock.

BTW - we have a 13BT beetle project too! shaweet!

karism · Post by **karism** » Wed Apr 16, 2008 5:50 pm

Dont worry,no hard feelings at all!