Centre console ready

With the fuel issues solved and a first test run, I can go on with the wiring ...
The centre console will be bolt between the transmission tunnel and the dashboard. For easy access, it can be removed, the electrical connection is realized with multi-pin connectors. An old power supply helped to check the wiring.
Cheers.

Kent Injection

The Jenvey fuel rails are connected with an aluminium tube, sealed by O-ring on each side. Not a happy setup if you ask me. I prefer a screwed connection, that's why I ordered fuel rails with Dash 06 connections each side...

... which made me run into the next problem: the connectors are too close to screw in a coupler. I had to cut two steel connectors and weld them back to back. This is not the final version of the fuel rail. The definite version will be of one piece, but it will be manufactured later.

With the fuel plumbing all done and ready, the ECU repaired and connected, I finally was able to start the engine.

Cheers.

Fuel issues

Emerald confirmed one of the injector drivers being fried, for whatever reason. Repair is done under warranty, although this ECU has more than two years. Talk about customer care! Just great!
With the ECU abroad I had time to have a look at the fuel plumbing and noticed a very small leak where the pre-pump filter meats the high pressure pump. Diameter is reduced from 15mm to 12mm and at the time, I hadn't found the best solution for plumbing this in. Everything is dismantled and I will chase the right tube and clips to do it right.

When I unmounted the fuel pump, I found out that a harness without connectors might be light and have less points of failure, but it is difficult to quickly unmount a device. Saturday was soldering day, the pump got a connector. And I started to wire the fuse/relay-box.

Cheers.

Injection trouble

Ideally, the engine would have started with the injectors plumbed in and connected. My son had the privilege to fill the tank. Unfortunately, injectors 2 and 3 sprayed even with the engine stopped. I didn't see it and cranked the engine, which means it went full of unburnt fuel without starting. First I doubted the injectors, then I assembled everything with the injectors hanging loose ... only to find out that the injectors are ok (swapped the connectors, swapped the injectors, checked and double-checked the harness).

The injectors spray away from the engine bay and I can watch what happens, measure the harness resistance, check the pins, read the voltage a.s.o. I sent all the data and the map to Dave and Karl at Emerald and hope they can help.

With the engine full of fuel, there are some things to do prior to start the engine again (or try to). My method was to unmount the exhaust and with the help of some hose and tissue catch the fuel that already had been spit out. Then I put out  the sparkplugs and cranked the engine (without ignition!!!) ... which means fuel spraying all over the place! What a mess! Even with lots of tissue around, it's very impressive to see how high and far it sprays. After this, more fuel catched in the exhaust. 

For the next tests it will be ok, but before I start the engine for good, I will also change the oil which is contaminated with fuel as well. Now I have to wait for an answer from the ECU manufacturer.

Cheers.