Andrew's '93 NA6 - KL V6 swap

[red devil]

The only thing you haven't built! progress is looking good

[Beelzeboss]

The only thing you haven't built! progress is looking good

It sure seems like it, so many custom parts needed to get this thing together.

Today I made YET ANOTHER 36-1 wheel, this one for the new pulley. I never want to have to make another again in my life, they take forever!

6 tooth wheel which came with the pulley



New 36-1 wheel



I also took some pics of the lower intake manifold which I ported out a bit. It's not perfect but the dremel takes ages to remove material.





I didn't manage to get the car started this weekend, only because I found out Saturday morning that I have a pretty important test on Monday. Hopefully next weekend we'll all hear it run (I'll post a video). All I have to do is fill it up with oil, connect all the lines and wires, do a little bit more wiring at the ECU and, fingers crossed, it should start up.

[Bizi]

Thanks for the update; focus on the exam material and get back to us when you're ready for the 'main engine start'.

For us dummies who don't get into the detail of designing engine parts, what tuning or other benefits will you get my machining your part into this multi cog setup?

This project looks so much more involved than the 1990s M2 1006 3.0L (hi-po ex-929 V6, RX7 diff & front suspension) project.

[Beelzeboss]

Thanks for the update; focus on the exam material and get back to us when you're ready for the 'main engine start'.

For us dummies who don't get into the detail of designing engine parts, what tuning or other benefits will you get my machining your part into this multi cog setup?

This project looks so much more involved than the 1990s M2 1006 3.0L (hi-po ex-929 V6, RX7 diff & front suspension) project.

The main reason I'm going to a 36-1 wheel is that I've eliminated the cam sensor (due to fitment issues), so the ECU can't tell when top dead centre is with just the standard 6 tooth wheel. It gets this info from when the missing tooth comes around. Also having 36 teeth rather than 6 gives a higher resolution signal for more accurate ignition and injector timing. I don't need a cam sensor because I'm using wasted spark and semi-sequential injection.

[Beelzeboss]

Well, it looks like tomorrow might be the first start (or at least the first attempt )

I got the ECU all connected



It wouldn't boot up properly, then I realised one of the grounds wasn't connected. After I fixed that I installed the latest firmware and did a few checks. The injector test worked fine but I could only get coil 1 and coil 2 to fire, coil 3 appeared dead. I figured it was unlikely the brand new OEM coil was defective so I checked all the wiring and isolated the problem as the ignitor that I made. The 3rd BIP-373 coil driver wasn't working, I probably overheated it when I first soldered it. Luckily I had a spare and once that was installed everything worked properly.



Here's the ancient Toshiba laptop which I installed XP on and the WARI tuning software. It has a serial port which works but the screen only goes to 800x600 so quite a bit of the tuning ap isn't visible.



Here's a shot of the engine bay.



All that's left to do before I can start it is to put on the intake manifold, add oil to the engine and gearbox, torque up the front crank pulley and plug in a few wires.

I also made a screwdriver key





Well, what else do you do with a broken screwdriver?

[twinlol]

Good luck mate, I have been following this build with interest since you started, very good work!

With regards to the screwdriver key, there might be a small business opportunity in that for you, it looks quite cool! lol

[rxmx]

Nice work mate, best key I have seen

+ the car obviously.

[Bizi]

LOL at the key! It will get a ton of laughs.

Fingers crossed that you've got it going.

Greetings from an amazing hotel room, overlooking the Marina, in Cairns!

[Okibi]

I've always wondered if people get an interesting reaction from the cops at an RBT with a screwdriver key.

[bruce]

Yup, screwdriver key is too suspicious!

[NitroDann]

I really like the key! Best part of the build so far! haha

Dann

[Beelzeboss]

Hehe thanks guys, I love how the key turned out.

It's a good thing I didn't have people over for the first start Basically this is what happened:

I connected everything up with the spark plugs removed to turn the engine over and get some oil pressure.
When I turned the key the starter solenoid clicked once and then the whole car went dead; ECU, gauges, everything.
I checked the fuses and they were all fine, but still the car was dead
I tightened the battery clamps but it was still dead.
Then I removed the positive clamp from the battery for about 10 minutes and reconnected it... everything works again... weird
I tried to turn it over once more with exactly the same effect.
After lunch I reconnected the battery positive to have one more go and it cranked perfectly on the starter.
The injectors were firing and everything sounded good so I reconnected the spark leads
Here's the weird part, now I have no spark at all. When I push the 'Pulse ign' buttons in the ECU software it does nothing, where just yesterday it used to make a good looking spark.
I've tested connectivity between all wires and it's all still good, no burnt out wires or shorts.

Basically I've somehow fried either the coil, all the BIP-373 chips in the ignitor or the ECU's ignition circuit. I think it's unlikely to be the coil because the BIP's would have been destroyed long before that happened, and the ECU functions perfectly apart from not generating a spark so I think it's unlikely to be that.

So, somehow I've destroyed the ignitor chips (unless someone knows another reason why isn't working) and I can't start it until I get some more

[Beelzeboss]

OK, so a massive update! I found out the ignitors weren't working because I had bent the pins a bit too much and a couple had come loose from the chip . Rather than ordering some more from the US and waiting until they arrived I found out that heaps of Mitsubishi's including Magnas use a Bosch BIM-034 single channel dumb ignitor. One trip to pick and payless and I had 3 of them.



Once I wired them up I had some weird issues (spark causing ECU to reset and fuel pump to prime and all sort of weirdness) but that turned out to be because I had only one spark plug plugged into the wasted spark coil for testing. Once I put two spark plugs in it worked perfectly... AND THEN IT STARTED!!!!!!!!!







FINALLY, it's alive.

[Jace]

YAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAY!!!!!!!!!!!!!!!!!!

[lightyear]

Skids video next