So what a few weeks of hell ive had with the car!! 90% of it fueling, some spark related and also a starter motor to throw into the mix.
I started getting the occasional miss fire under boost and had a coil pack on number 4 fail which i suspect was due to heat. Following this I set about a coilpack conversion to move the coilpacks away from the heat and to make #4 easier to access following a slight design flaw on the manifold wastegate placement lol (will be getting some longer leads as well as don't like how tight they are, i didn't mount the coils in the original position i had planned)
Whilst it was off the road i had also planned on a couple of fueling system changes, i changed the rail feed to -8an from -6 to cope with the extra flow required and hopefully reduce pressure drop making it easier on the pumps, at the same time I relocated the fuel filter to Just before the rail. I even had Freddie get all keen and try and help out. Got to start them young
Cheeky little look on his face. Strict instructions from the Mrs though the children are not allowed in the "racecar"
Addition of once again another cooler on the car.
Upon running the car after it had sat for some time i found that I'd only get a few miles down the road and the car would start to misfire and die on me, it done this to me a few times and had to get the mrs to come and recover me and the car much to her disgust.
It was really hard to pin point what it was causing this, spent many hours thinking monitoring and trying things, i relocated the fuel pressure gauge into the car to help with diagnosing the issues.
It turns out my surge tank was running empty and pockets of air were being picked up causing me occasional misfires on longer pulls, this got worse and worse over time until it got to the point the car wouldn't run and the gauge pressure drop was evident. Upon much more digging, it would turn out to be that the DW65V intank pump doesn't pick up from the other saddle without load against the main outlet. Usually main outlet is minimum 3 bar but on mine with the surge tank etc it is absolutely minimal which causes the suction jet/venturi system for other side pick up to not function correctly. I found that by putting a clamp on the feed line to make it build pressure solved this but was inconsistant.
Next up was dyno day which had crept up far fa to quickly and wasn't prepared as would have liked to have been.
Car strapped in at street racers
We quite quickly was greated with occasional misfires after multiple pulls etc, which shockingly again was the intank pump not picking up from the other side of the saddle, brimming the tank sorted this.
Not long down the road we hit the same sort of issues again but the tank was pretty full. Upon pulling the intank craddle out and dismatling, it was very apparent what had been causing the next round of issues. Swollen o-rings becoming unseated.
A quick bit of pikey modifying sorted this issue though and the pump functioned with no o-rings in the basket lol
After a morning of irratic fueling we was hopeful that the afternoon would bring us more Joy
Gordon started by trying to get a nice steady base boost profile around 1 bar across the board, had occasional reocurring misfire on boost, after changing the plugs we brought the gaps down from 0.7 - 0.6mm, this certainly sorted it. For now!
We then started to put some a little more boost into it up to 1.2 bar but was greated with more occasional misfires again. We started hunting high and low trying to work out what was going on until it progressed and started running on 3 cylinders
This turned out to be a dead coil pack which i may add was brand new 2 weeks prior!! Luckily i purchased 5 so would be covered.....I left the sodding thing at home! B******KS
We ended up proceeding by linking a Honda coil in that was knocking around to get us out of Jail so could progress on,there was nowhere that we could find a new coil to purchase, to drive to pick mine up is a 5 hour round trip.
Thinking we was getting somewhere now and all this was behind us he started mapping again.
Once again after some time we discovered that the fueling system just wasn't keeping up, and this time it was the 044's. It took a few runs and a little while before we realized that fuel pressure was dropping off during the pull but not the same characteristics as before with air being drawn in.
By this point we flew the white flag and called it a day as knew that there was no point progressing. Below is a couple of graphs and relative logs.
On this run it did have a bit of a boost spike but fueling was rich at the same time robbing power at that point as went below 10:1 afr, but does most certainly look promising making 400hp @ 1.1 bar boost at as low as 6700rpm.
Next one was more of a test run to accentuate the fuel pressure dropping with a boost pressure to raise fuel pressure. We saw it dropping by nearly 1 bar nearer the end of the run.
Once again running rich made the power start to tail on the graph but very happy with how the potential of how this setup is looking certainly wasn't expecting it to spool and make this much power this low down for the size of turbo. 420hp at 5300
All in all what a ****** pain in the **** it has been but the potential is looking massive once put some real revs in there as hope power will still keep climbing without finding the point of leveling off like the HTA3586.
Wondering if will see the main bulk of the range of the new 5 bar MAP sensor as well as expect it will still keep gaining power around 3 bar region....who knows?
Cant wait to get it mapped full with timing and boost suitably optimized to find out though