PFF - Pennock's Fiero Forum, PDA Edition

The Turbo 3500 F23 swap (Page 58/80)

ericjon262

NOV 27, 10:57 PM

good news! with the addition of the new battery, the throttle appears to be syncing up! I suspect the cranking voltage was too low for the DBW unit to maintain the throttle operating, so it said "F-this, I'm out".

Tomorrow, I'm gonna head to the parts store and pick up some coolant, and try and see what I can make happen with the idle.

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"I am not what you so glibly call to be a civilized man. I have broken with society for reasons which I alone am able to appreciate. I am therefore not subject to it's stupid laws, and I ask you to never allude to them in my presence again."

cognita semper

ericjon262

NOV 28, 04:44 AM

With the new battery, comes a new, unexpected problem, my MAF either a) isn't outputting a signal or b) the signal isn't making it to the MS3 pro.

So far, I have verified the MAF signal wire is wired to the correct MS3 pro pin, then I checked power and ground on the MAF sensor. everything seems to check out good, I'm going to order a new sensor and cross my fingers.

I started working on a speed density "tune" to try and get it idling, and this thing sounds pretty nasty for a little V6, I'll have to try and get a camera with a decent mic and get a clip going.

ericjon262

NOV 28, 11:04 AM

New development! I looked at a datalog, and my IAT is all over the place, with fluctuations way more rapid than I would expect from IAT(20 degrees in 0.5 sec), and about 40-50 degrees colder than ambient... I checked again to make sure it's pinned correctly, but I suspect I have the wrong pinout, and the MAF signal is being transmitted over the IAT signal wire.

ericjon262

NOV 28, 07:05 PM

CHOP CHOP CHOP!

https://youtu.be/gIQ5aVr_l4c

The IAT and Flexfuel wires got crossed somehow... for now, I'm going to keep working on a speed density tune until I can get MAF figured out.

La fiera

NOV 28, 09:10 PM

quote

Originally posted by ericjon262:

CHOP CHOP CHOP!

https://youtu.be/gIQ5aVr_l4c

The IAT and Flexfuel wires got crossed somehow... for now, I'm going to keep working on a speed density tune until I can get MAF figured out.

Good job Erick!!!

ericjon262

DEC 12, 07:19 AM

quote

Originally posted by La fiera:
Good job Erick!!!

Thanks.

I haven't accomplished much in the past few weeks, I have smoothed the idle out a ton, but I'm still not getting a MAF signal...I'm going to try adding a pullup resistor and seeing if the signal works.

today, I got the blown front brakeline replaced, and I'm going to try and see if I can get the roof skin fully installed so I can call a windshield installer on monday.

I've got a ton of little stuff I need to do to try and make the car move under it's own power, the abridged list looks something like this:

attach the front left brake hose to the UCA(I don't have the right rivets on hand...)
bleed/flush the brakes
bleed/flush the clutch hydraulics
bleed the cooling system better (I think there's an air pocket in there...)
Check torque on all the rear suspension and cradle bolts
get a windshield
Test the lights/get them working
Configure the microsquirt I/O box
lots and lots of tuning.

ericjon262

DEC 23, 09:23 AM

I've was making good progress on an idle tune, and then it started running like crap out of the blue. I suspect I have a vacuum leak. I ordered a smoke machine to try and find the leak, but I haven't had a chance to employ it yet.

I ordered a 3d printer for prototyping some of my drawings, First print was an intake flange for a 3500, I joined the ports and split the flange because the whole thing wouldn't fit the print bed in one piece. made it easy to validate my measurements. I'm pretty excited at the opportunity to start prototyping the different drawings I've been making.

There's a little bit of mess around the bolt hole, not sure what happened there. Low adhesion to the bed? There's several easy DIY approaches available to fix stuff like that. I'll investigate what I need to do later when it matters more.

Big picture plan, print the different parts, glue them together, and test fit. if things fit nicely, I might look into lost PLA metal casting for some cool, one-off parts.

ericjon262

DEC 24, 01:10 PM

survey says:

Plenum gaskets, or something under the plenum is the source of the vacuum leak. The car currently has OEM style metal plenum gaskets, which have an "o-ring" style seal. I figured they were probably the best available, maybe not though. I'm going to pull the plenum and smoke test each port to see if there's anything under the plenum like a bad injector o-ring.

The smoke tester was worth way more than the ~$50 it cost.

ericjon262

DEC 26, 03:33 AM

well, today seems really hit and miss...

it looks like the culprit is the plenum gaskets... erg. I had noticed the plenum wasn't perfectly flat on the lower after welding, but it was pretty close, and I had hoped it would be close enough, but I don't think it was... For now, I did the unthinkable, I took some 120 grit to the suspected high spots, it's way closer now, not perfect, but closer. If I have further problems, I'll take it to a machine shop and ask for perfect. by the time I had it back together, it was a little late to be firing it up (I'd rather not be that guy in the neighborhood...) the real fun happened while I was re-installing the plenum, and 2 of the bolt holes decided to become "righty loosey"... they're snug-ish, but I ordered a time-sert kit because I'm confident this will be a problem later.

on another front, I went to bleed the brakes, and couldn't find my mighty vac... ERG. I decided to try just leaving the bleeders open and letting it gravity bleed until I could pick up a new mighty vac, and while it was sitting there, I decided to pump the pedal. shitloads of air came out, as expected, but it didn't go back?! years ago, I installed "speed bleeders", and totally forgot! :Yahoo!:

I didn't have a speed bleeder on the clutch, I was more than positive of that... this one required a bit more creativity... I got the shop vac out and taped some tubing to the end of the hose, turned it on, cracked the bleeder... it was slow, but it appeared to work... lol. I'll probably pick up a new mighty vac on my way to work and bleed it a little better.

I had a set of koni front shocks that had been sitting on the shelf for the past 5 years or so, I threw then on while I had the front wheels off for bleeding the brakes. I ordered a bunch of rivets for my big rivet gun so that I could rivet the front brake line to the control arm like factory, but then after a remembered that I have a riv-nut gun, so I put an M5 riv-nut in the control arm and ran an M5 screw through to hold the brake line.

back to the rear of the car, I had a straight hose end coming off the boost port on the volute of the turbo, and it was interfering with the air cleaner installation. I've had a 45 degree end in my cart on summit for about a month, but I looked on the shelf today and realized I had one right there the whole time! this one is blue and red instead of black, but it's not in a visible spot so it doesn't really matter.

I also tightened up all the suspension parts that I still hadn't tightened from when I took the engine out.

I had a coolant leak at the radiator, near the cap, I had been suspecting the cap was failing to seal, after it still leaked with a new one, I got a little frustrated and walked away. today I noticed the leak again, poked and prodded, and realized it was the crappy hose to the overflow bottle. replaced it, and now it appears to be leak free!

I'm really hoping to drive this POS at least down the driveway and back into the garage before the end of the year... I'm running out of time real quick, but I'm also pretty close... maybe not close enough though...

ericjon262

JAN 01, 11:21 AM

Closed out 2020 on a high note, 2.1 miles down, countless more to go! I have a ton of tuning to do to get it right. Max throttle position was about 50%, I set limits in the software to keep it below about 30% until I get the tune a little more dialed, and I'll slowly step it up from there.

https://youtu.be/ky8ip6b152Q

I think I need to swap to a larger master cylinder, the brakes don't respond quite like I hoped, but I also have a stock master, with 2 piston C5 'Vette calipers on all four corners, but for now, what I have stops the car OK.