mk1cossie

Please help again somebody, finally got my cossie engine running but it will not rev and at idle its putting out alot of black smoke. As soon as i try to rev it, it just goes to cut out. I have changed the phase sensor, temp sensors and the one in the inlet manifold.

MrC

ACT sensor

studabear

Is the map sensor connected ok?

Over fueling from the sound of it.

martysmartie

iTrader: (1)

The one in the manifold is the ACT, I doubt it's that!

It sounds like a MAP sensor, sometimes the sensor isn't the problem, but rather the reference hose, which if it has come off the inlet end or the sensor itself will make it run extremely rich!

Martin

boost mad

iTrader: (8)

Which temp sensors have you changed ? The Blue one in the back of the head ?

If you have changed that one and checked the associated wiring, then i would go as Martin has said

MrC

Your right Martin it's not the act that's the brown one
Sorry I meant to say the blue one at the back of the head, it's the water temp sensor right??

mk1cossie

Yes ive changed the blue and the brown one, ive moved the map sensor inside the car as its in a mk1 escort so it has a long vacum pipe would this make a difference. Ive also fitted a 044 bosch fuel pump would the pressure need adjusting?

martysmartie

iTrader: (1)

Correct, OP has also changed this, in actual fact there both the same sensor, just in different housings.

Think this is going to be your problem, I am sure the hose has to be fairly short as I would imagine the signal can get distored over distance. It's worth moving it close to the engine and trying it with a shorter length of hose to test.

I don't think so tbh, as it's only when under demand the pump delivers the extra fuel, in theory I should think under normal conditions the fuel delivery would be the same? In other words so long as the pressure was set correctly in the first place you should be ok.

Martin

mk1cossie

I will have ago and move it tonight to see what happens, thanks.

mk1cossie

Just moved the map sensor next to the inlet manifold and it didnt make any difference unfortunately, also checked the fuel pressure and its running at 35psi the chip in the ecu is about 280bhp?. Also tryed the old temp sensors but nothing, its like it wants to start to rev then just cuts out until i let the throttle off.

mk1cossie

My brothers cossie should be out the bodyshop by the weekend and i have permission to try his map sensor etc, fingers crossed. But in the mean time any more ideas anyone. Thanks for all your help.

martysmartie

iTrader: (1)

I presume you have a calibration suitable for your engine spec, generally speaking a "280 HP" chip is known as a stage 1 chip, named so as this is the power that is expected, and this means standard injectors, turbo etc, which I presume you have?

What is your engine spec?

I still say though it's something to do with the MAP sensor, possibly faulty, do you have a 2 BAR or 3 BAR item?

I should think yours will be a 2 BAR item as this is generally what would go with your software calibration.

The fuel pressure seems a bit low, it should be around 3.5 BAR from memory with the vaccum hose disconnected.

Martin

BRAM

iTrader: (1)

Are you mounting the map sensor pointing to the floor so you have to push you vacum hose up, just somthing that i got told a few years ago that that is the way they are supposed to be mounted to work correctly.
Not sure how true this is im sure someone will correct me if im wrong.

But does sound like map sensor problem.

boost mad

iTrader: (8)

What ECU and what TPS ?

kosienutter

I might be thinking of the wrong thing here, so sorry in advance but Is there a way IIRC that you can accidentally put the TPS on the wrong way round???????

Plus if your set up is for 280bhp then you should be running a 2bar map sensor I think.

boost mad

iTrader: (8)

I'm thinking that , well sort of.

The tps will only go on one way but can be badly adjusted. Other option is that the outside wires have been swapped to make the loom compatable with L8 or L6 .

kosienutter

Ahhh badly adjusted sounds more like it.

martysmartie

iTrader: (1)

If L1/L6 car will start and idle without a TPS at idle, as the correct TPS is open circuit anyway at closed throttle, 4x4 could pose a problem I guess as that needs to see a voltage, still think it's MAP related myself.

Stage 1 is the standard 2 BAR MAP sensor, 3 BAR isn't needed as it's not making the boost to require it.

Martin

mk1cossie

I had it all running in my sierra about 3-4 years ago, since then all ive done is rebuild the engine internals and replace the temp and phase sensors, it is still running the same map and tps sensors, I think its a 3bar map sensor and i dont remember touching the tps sensor adjustment. Hopefully be able to pinch my brothers car by the week end to test my parts. Out of interest where should the tps be sitting in relation to the adjusting screws or is there another way of setting it properly. Phil

cossie moon

Map sensor needs to be on upside down and the pipe needs to have a dip in it so its lower than the sensor to stop petrol fumes getting in and causing sensor to fail!

mk1cossie

I put the sensor upside down and used the original ford elbows with a longer piece of pipe in the middle before i started it. but will defo double check when i use my brothers one. Phil

martysmartie

iTrader: (1)

Like I say for a stage 1 chip which sounds like your one, you need a 2 BAR MAP sensor (The scales are different between different versions), otherwise this will cause problems as well.

Martin

mk1cossie

Ive put on a new map sensor and its still wont rev, if i bring the throttle on very slowly it will rev but if i push the throttle normally it will just cut out aaaaaahhhhhh i love cars.

martysmartie

iTrader: (1)

What is the TPS output?

Martin

botters

iTrader: (2)

are the plug leads in the right order and quite a common thing for overfuelling after a rebuild is putting the idle valve connecter onto number one injector by mistake, its easily done ive done it myself lol

mk1cossie

I havent checked the tps sensor what should the readings be, was going to try my brothers . Its not missing at idle or when you gently rev it, Defo not the wiring on the injector but thanks anyway

martysmartie

iTrader: (1)

It should be open circuit at idle and with the slightest throttle opening the switch will close and the reading should DECREASE the more the throttle is opened, @ WOT expect to see around 0.5V or so.

Do you have your phase sensor setup ok?

Martin

mk1cossie

Tryed my brothers tps sensor and no different, on the bench they both give the same ohm readings will try readings on the car. I have changed the phase sensor should there be a gap setting. I ran it with a spark tester in between the plug and ht lead when i go to rev and it cuts out the spark is still going strong so it doesnt seem to be spark. Phil

Stu @ M Developments

iTrader: (12)

Not sure why everyone has missed this but your fuel pressure is FAR too low for starters, should be at 3.5bar with pipe off.

When you rebuilt the engine, are you sure you got the phase alignment correct?

mk1cossie

What should the alignment be as put the new phase sensor in a while ago, cheers Phil.

j888cag

sounds like way to much fuel and have you tryed a ajustable fuel pressure regulator???
play around with the settings and find a happy medium

worth a try

cas

MrC

Or an injector stuck open, I Had this on mine

mk1cossie

got settings for different sensors and will change injectors and fuel pressure tonight, fingers crossed.

martysmartie

iTrader: (1)

I diden't

Martin

mk1cossie

As i found out i had already set fuel pressure as Martin had already suggested, doh. Anyway ive set all adjustable gap settings, phase, crank and plugs, redone the timing belt just incase even changed the fuel and still cutting out when i go to rev. Not sure if this should happen but changed the no 3 & 4 injector wires over as im now going insane and it still idled nice!!!!!! but wouldnt take revs. It was not as nice with 1 & 2 changed aswell but still idled. Could this be a wiring fault as the loom is getting on abit.

martysmartie

iTrader: (1)

What injectors do you have?

The injector plugs corrospond to a cylinder, i.e. you can't just plug them on anyone.

What can happen is a injector can have a permanant ground, due to the earth wire for the injector becoming chaffed and shorted etc, but then it will massively overfuel as obviously that injector is permantely open.

Do you have any noid lights?

Martin

mk1cossie

It has dark greens but i do have a set of yellows. I dont have any noid lights but i might be able to get some. So basically plug it in place of injector and it should pulse? Phil

martysmartie

iTrader: (1)

Thats why I asked, you should have standard injectors, i.e. "Yellow's" for a stage 1 tune which is what you say you have, it's worth a try swapping the injectors!

Martin

Stu @ M Developments

iTrader: (12)

Sorry mate, I must be blind.


Mate, you will never make any progress at all using the wrong injectors for the chip.

mk1cossie

Could it be a problem with the loom, moving it from one car to another, as 3 years ago it ran well with this set up in my sierra. Confused Phil.