Getting the Engine Running,the Saga

[karism]

Morning Guys!Since I bought my 200sx in a non running condition, there were some things that needed tending to.Firstly : the starter would turn for quite a while, backfire a good couple of times trough the exhaust, and then fire up. Ran for about 1 second ,and then died.

To me, this spelled one symptom…. Ignition Timing! Now I’m not very knowledgeable with Pistons engines at all. Although I understand it, and have modified quite a few of them, the thought of 16 valves, 4 pistons, little sticks being turned with a belt just generally scares the crap out of me.

So the help of Turbonutters was called in.

We removed the CAS, and there was a very nasty surprise for us there…The drive in the exhaust cam, was broken off. It didn’t seem like it was the result off abuse, but rather it got worn out slowly over the years. What to do, what to do?

Decided a new pin would do the job! So we took a piece of high tensile strength shaft, and turned it on the lathe.(refer to the pics please)We knocked the new pin in, and reinstalled the CAS. Setting the timing roughly.

Turn the key…chi-chi…VROOM!It was purring like a small Ginger colored kitten!Yeehaaa! Ride em cowboy!

Ran smoothly for a few minutes, and then it died. Oh crap. What now????CAS came out again. The brand new machined pin, had broken off. Halo??Was the machinist drunk by any chance?(Actually, slightly intoxicated, as were the rest of us,hahaha)

The Exhaust cam pulley had some scuff marks on it, where the new pin was grinding away..

What do we do now?

I took off all of the front engine covers, radiator cowling, cam belt and various other weird things that 4 cylinders use! I was making sure that the broken off pin wont cause poo-pee. We found at them bottom of the crank pulley. Thank goodness!

What to do now?Installed everything back where it was supposed to go. Took off the exhaust cam pulley, and made a slot in it. The little slot will provide a space for the pin to fit into, and not break off again! Arrrghhh! We be clever after beer!Fitted everything in, and it was once again running like a ginger colored kitten!Part 2The Sx was running fine with the CAS working like it should. It started on demand, and drove well.

My brother came to look at my new toy , and take it for a spin. (Does feel weird sitting shot gun in your own car, doesn’t it?)During the spin, he looked at me, and said that the engine is pining! I was worried, real worried. We all know pining lead to knock, and knocking leads to conrods, valves and other bits coming outside for a little ”visit!”

I retarded the timing, and the pining got better. It was less pleasant to drive now. ..It didn’t want to spool so quickly anymore, and the thrust was much less fierce. I was disappointed, real disappointed.

On Sat we put buttcrack racer (My lovely Sx) on the CO machine. The specs said the Co level should be 2.0 max. It was running 0.2 !!!! How in hells name was it even starting up with a mixture that lean? We tried adjusting it on the AFM for a few minutes, but it made no difference.

We then directed out attention to the fuel rail. I know some of the Sx`s had the knack of loosening their own injector plugs while driving. Butt was doing fine, all of the injector plugs were nice and snug.

Next we decided to have a look at the Fuel filter. Removed and had a suck through it. * Mental note :Next time try blowing, fuel does not in end up in lungs that way*

It was flowing fine, no obstruction.

Next up?

We took the fuel supply pipe off, and added a pressure gauge to it. Any proper EFI pump should push in the region of 5-6 bar when unregulated, and pushing directly into the gauge. I was getting a reading of 30PSI , which is about 2.2 bar. Arrrggghh! We be found the problem! hahahaWe headed to Autozone, and bought a nice universal pump. It was made by Bosch and fitted easily with some small mods. (I was trying to get AWAY from the German products, but Murphy is always around)

I fitted the new pump… ARrrrghhh !!! It be purring like a kitten!

Took it for a little spin(haha, no pun intended) around the block.Holy Cow! What a difference! It goes like the clappers now! Doesn’t ping/knock/break, and the Co is where it is supposed to be!My little Buttcrack racer is healthy, idle is stable, and does not show any signs off general unhappiness.

A VERRY happy ecstatic 200Sx owner!

[dattodude]

The refit of the front cam-pulleys cover fixed the problem, it wasn't installed properly. The steel bezels align the backing plate, and keeps the CAS mounting surface perpendicular to the camshaft.

Breaking CAS shafts has been seen and done dozens of times before. Be thankful it didn't snap the camshaft.

Good work on surviving the first few days of CA18 ownership. It can kill ya if you aren't careful.

[ca18detgabby]

Good work on surviving the first few days of CA18 ownership. It can kill ya if you aren't careful.

word!

+10 to the OP for not giving up and selling it because you cant fix a problem either. so sad day in and day out to see them going by the way side.

kudoos to u!

[karism]

I`am glad i could fix it.Was kinda nervous buying a non running Sx.But int he end it was worth it!

[r34 gtr]

Congrats on getting her running! I was very glad to see you didn't take any crap from the motor, and got it running like it should.

Do you have any pictures of the 13b Beetle? I would love to check that out. I'll bet it does wheelies.

[boost_boy]

word!

+10 to the OP for not giving up and selling it because you cant fix a problem either. so sad day in and day out to see them going by the way side.

kudoos to u!

Stay tuned ! Dee

[karism]

I have some pics of it,allthough i think the guys would throw me with bricks if i post a non piston engine car?

Its not running yet.it a hard process to get everything done.I think it will be worth it though!

[ca18detgabby]

Stay tuned ! Dee

it is getting crazy. On the upside parts from others engines are getting easier to find. I picked up a second intake manifold....... time to start drilling for cheater juice

though Im going to polish this one up nice too.

[ca18detgabby]

I have some pics of it,allthough i think the guys would throw me with bricks if i post a non piston engine car?

Its not running yet.it a hard process to get everything done.I think it will be worth it though!

no its ok........ those engines make my 1.8L look HUGE!

[karism]

Before : It stood under a tree for 10 years.Needed loads of work





after loads of sanding ,and painting





Header took over 6 hours to build with the help of 2 friends.Pipes differ in lenght by exactlyy 0.03 ".Started with a piece of straight pipe,and a cut off machine.

[karism]

Engine shot currently. Please note : The intake manifold was sanded by hand,and then buffed.It took more than 1 month to complete.(I dont like power tools)



Side Shot.



Front shot.

Disc Brake Conversion. Golf 2 GTI 16V Cross Drilled Discs and Calipers.



Reference shot : What the intake manifold looked like



Specs :

[karism]

Specs :1974 Vw BeetleSeries 4 4 Port 13B RotaryFlowed Throttle Bodies (all 3 off them)Custom designed and built header (Pulse tuned Collector,15Deg angles,with deflector plate)Thick wall 2.5 “ piping to withstand temp. Stainless”bomb” slincer. 2.5 in and 4 in out. Baffles with rock wool,once again for tempFord Tp500 ignition system. HUGO coil wires.Bosch 40k Volt coilsVW 16V Radiator- 2x 12” Spal Fans from Italy(Alu radiator,plastic caps)25 Row Motorcade Full Flow Oil coolerMedia Stainless steel braided Oil pipes. Guaranteed to withstand 1500 Deg F external temperatures, ultra flexibleGolf 2 GTI 16V Cross Drilled discs ,and GTI calipers.GOLF master brake cylinderCustom rear suspension adjustable Z bar.Gabriel Oil Shocks (more controlled movement)Ultralite 15” wheels,to reduce unsprung weight1000 Pound clutch Pressure plate.17 Pound custom machined flywheel (includes counterweight weight)

Inside :STP Gauges (RPM ,oil temp ,water temp, oil pressure ,AFR ratioFord Escort seats with custom covered door panels, and carpetsEmpi short shifter

Well,that’s what I remember off hand

Karis