phocup

I just finished swapping a 99 into a 93 chassis. She first fired up 2 days ago on July 24 ( https:// www.youtube.com/watch?v=OI-BbxDCBBw ).
Woo hoo!

Started her a few more times that day and she was running well enough for me to set timing to 10. I didn't really run her too long because the cooling system wasn't plumbed yet.

Was busy with work most of yesterday and spent today doing the final prep to drive. All mechanical stuff like reinstalled ppf / drive shaft / tranny fluid / exhaust / shifter / sway bar / radiator / speedo cable / throttle cable. Nothing electrical that I can recall.

Fired her up again earlier excited to go test drive and got a big fat rejection. No start. WTF!

After a few try I noticed that FP wasn't coming on when I turn key to run. Normally its clearly audible.

What I tried:

1. Tried to jump F/P and GND, turn key to run again, nothing.
2. Kept F/P and GND jumped, with key in run position, tested voltage on the fuel pump connector. 0V shown on 3 wires. Only yellow wire ( going to dash fuel guage ) was reading 8V.
3. Checked voltage from GND to B+. Got 12.8V.
4. Checked voltage from GND to F/P. Got 0V.

So IMO, test 2 and 4 seem to point ( IMO ) to fuel relay .. but .. if that was the case, test 1 should have worked and started car by bypassing fuel relay ?
Does test 3 proves main relay is good ?

Thanks.

Braineack

iTrader: (62)

test 3 proves the INJ fuse and Main Relay are still functioing.

you may want to check the MAIN fuse and STSIGN fuse.

phocup

Braineack, you're the man. PM me your email and I'll gladly send you a starbucks card as thank you.

Its the ST Sign Fuse. I took it out previously when installing MS perhaps 2 weeks ago. Never put it back and was able to start the car fine multiple time since though never really drove it !!
However, this time it wanted the fuse to start ?

Poking around a bit it seems others are able to drive fine with that missing fuse as well. Some post suggest it controls fuel pressure and I would have issues if there was no fuel pressure. If that was the case I would expect this issue to happen when I first installed motor, not now after motor has been ran several times. 100% sure when I was testing fuel system during motor install a few days ago with fuse still out I was able to hear FP coming on and know it was pressurizing the line because I immediately had a fuel leak issue I had to fix after turning key to Run.

Strange!

phocup

So finally got my test drive the new motor today. Man .. she sure looks good .. but runs and sounds like sh*t. Couldn't even make it around my block without dying. :(

Video 1 ..
ISSUE #1. Squeeaaaaaally motor even with the accessory belt off. My guess is maybe timing belt needs adjustment ? Any other possibility ?

ISSUE #2. Some demonstration of the hesitation / idle drop issue with me playing with the throttle cable. My guess is leak in the intake air tract. We'll have to play with that a bit.

ISSUE #3. The worse problem of all. The slightest touch of the clutch creates a continuous knocking sound that gets worse and worse as I press the clutch down more. Car does get into gears fine. Shifts feels fine. Everything I'm researching says throw out bearing, which is brand new Timken NTN bearing. I made sure it was sliding smooth pre install and in the correct orientation. Not sure what could have gone wrong here if the throw out bearing is indeed the issue.

Video 2 ..
Really highlight the idle drop issue #2. Main problem seems to be with quick throttle input.

ISSUE #4. Tranny seems to be spraying out tiny amounts of oil. Not a huge issue right now, but perhaps need a new transmission soon especially if I have to pull the tranny for issue #3.
https://lh3.googleusercontent.com/-yEFErwo6nPs/WXpCdDXVwdI/AAAAAAAC3F8/1SVEEhH0sjg6RnEj1wMvsnvvor_qEgYNwCL0BGAYYCw/h2220/7053849509700928775%253Faccount_id%253D1
A few months ago I did notice a leak but have been topping off tranny fluid and running it as is.

phocup

Still chasing the noises above .. waiting for my timing belt kit to come so figure I would pull and replace the trans with a spare 5 speed.

Upon removal, throw out bearing looks like install correctly and so sign of damage. It does have a certain amount of free play with between the lever / shaft / bearing assembly though. Not seeing anything that could be tightented up more. Can anyone tell me if this is 'normal' amount or if perhaps I have defective part somewhere in there ?


Now if that banging sound when clutch pressed in is NOT throw out bearing .. next to replace is clutch slave ?