WOW...so it's been a while since I've been on these forums or updated this thread....so here we go...it is FINALLY running again. I had a lot of pauses on the build due to many many life events (getting married, having a house built/moving, going through the police academy, having a baby boy), but I managed to stick it out and not give up on the car, which brings us to this past Saturday where we FINALLY got it running again.
If I remember correctly (i.e. reading from my last post in here), the car was at the shop waiting to be trouble-shot and tuned...well I gave the shop a month to figure the car out, and they were unable to...so after a frustrating month, I decided to pick the car back up and bring it home. My brother, my buddy Aaron (Hummer96 on 3ZC...not sure if he's on here, or what his username is if he is), and I decided to start tracking things down ourselves. After countless hours of checking continuity between connectors and haltech pins, we came to the conclusion that something in the haltech flying lead had actually shorted and was crossing with the grounds. That being discovered, I pulled the flying lead off and wires the OEM harness directly to haltech ECU connectors. In hopes that this would solve the problem, we gave it a shot...no dice. All it would do was crank. We checked everything we could think of and were coming up with nothing...after a couple different attempts with pulling the harness and removing some unused wires and connectors, we found that something in the stock relay box was now not playing nicely with the now slightly modified harness.
That being said, the next thing on the list was to completely pull the EFI harness back out and build a fully custom one. I essentially yanked every single wire and connector that was not being used out of the harness and again wired directly into haltech connectors. I also added built in relays for the ignition circuit, injector circuit, and ecu/sensor power. After a little bit of fiddling with the setup of the harness setup, we still couldn't get it going. We did a little more trouble shooting, and found that 2 of the 5v regulators in the haltech were bad...one was putting out about 6.5V and the other almost 9v. We replaced them with new regulators and viola, she started right up. With the old map loaded in we were actually able to drive the car again! The idle could have used a little help, but it drove and was fairly smooth. All exited, I contacted the guy that was originally tuning the car, back when it actually ran, and set up a day to try for round 15 of street tuning. That day came two weeks later, and viola...the car wouldn't start...again. After a couple hours of trying different settings, we called it a day. I pulled the plugs and saw that they were absolutely destroyed with carbon and fuel. My tuner sent the map to haltech and I ordered a set of new plugs (NGK BKR7E copper plugs...rather melt a plug than a piston). A couple days later my tuner emailed me a completely new map (haltech recommended a couple changes in the setup and he built a completely new VE tune), and my plugs showed up. (somewhere in there I also had to repair my shifter bracket bushing by welding in some angle steel as the support. I will be making my own version of a solid bracket once it's tuned...I also got a set of Ash manifolds and will hopefully be doing back to back dynos to see what kind of gains we get from just the manifolds).
Which brings us to Saturday...I made the trip back down to my parents house, swapped out the plugs, loaded the new map, updated the firmware in the haltech, and boom...it started right up. On a blind map (not made in the car), it started easier and quicker than it ever did before, and also revved smoother and faster than any previous version that it actually ran on. With this big bit of progress made, we let the car cool down and restarted it with no problems. We unhooked the battery, let it sit for about an hour, re-hooked the battery up, and it still started. Feeling like we made about 500 steps forward from every other time we tried something, we are now hopefully at the point where we can street tune the car again and FINALLY get it on a dyno! We are set up for this Saturday to touch up the map with a street tune, then it will be hitting the dyno (if all goes well). Since it's been so long, obviously I have some pictures of what we have done, and a couple video's too...so here goes nothing...
https://youtu.be/JIarr3LN4wk
https://youtu.be/FXnSWvFWwKE
https://youtu.be/uU4aC7tH1Q8