igor is dead

[themadscientist]

Fun fun, let's do wiring! I hate wiring

The Atrai harness does not reach far enough to just plug into the Hijet. I cut the harness and extended all the wires one meter. It was a lot of work.



Note to self. When a voice in your head, one that sounds like you, but older and wiser, tells you to cut and extend one wire at a time, LISTEN!



I had several wires that were the same color so I had to trace them to their source and match it with the wiring diagram. It's actually lucky that I had to do that, otherwise I wouldn't have noticed the alternator wire is broken.



I was lucky that the original Hijet harness is here so I could refer to it. A lot of the duplicate wires were bus connections for sensor and coil grounds. If I had noticed that I might not have cut so many wires. I am 99% sure I have it all back together right, but there's no telling until I try to start it up. Hopefully I don't fry something.



The junkyards want over $100 for a dinky stock intercooler and piping. Yeah F-U douchebag. I hit UpGarage and picked up a Mitsubishi Pajero intercooler for $8.00.



The inlet and and outlet are a little smaller than the throttle body and a little bigger than the turbo outlet, but it's workable. It also has a small pipe off the tank that is perfect for hooking up my blowoff valve.



Tomorrow I need to pick up some heater hose to run the coolant lines to the turbo. It appears the line runs from the motor then to the turbo then out of the turbo to the heater.

[float_6969]

I see tremors of life starting!

[themadscientist]

I finally found an Atrai with some parts left on it, that I could afford, and that the yard would throw up on a rack so I could get the s*** out!

Pile of pipes and hoses, check.



The Atrai mounts the intercooler all the way at the front of the van so there is a lot of pipework on one. I had plenty of bends and straight runs to do what I needed to do with some left over.




I picked up the Atrai intercooler as well.



After I have the vehicle running and I know everything is right, I'll run it over to a muffler shop and have the blow off valve welded on the straight run under the bed and fashion brackets to hold everything proper. Otherwise, the intercooler setup is functionally done.



Now, I got a lot of the water lines done, I still have a bit to do. I ripped the old oil filter off, screwed a fresh one on and filled it up with Mobil1. The cooling system is not done, nor is the muffler, but I figured I had enough done to try to start it.

I CRANKS! it doesn't start.................

I was losing light and i have been out in the heat all day so I decided after a few minutes of troubleshooting to call it a day. Before I wrapped it up I confirmed I am getting spark and I have continuity on the injectors. That doesn't mean I am getting fuel, however. I'll have to get that fuel pressure gauge hooked up. There is also continuity to the air temp and pressure sensors, there is no air flow meter. Spark tells me I'm getting a timing signal, but I don't know if it's correct. I've never shot time on one of these before. I'm confident I put the timing belt on correctly, but if other things check out I'm going to have to go back in and check that.

I'm not bummed out yet, but I am concerned.

[themadscientist]

Back to basics, the combustion triangle. What are we missing? Air, we got that. Spark, we have seen at least one plug go off and that would make something happen. Fuel? I pulled the line of and flipped the key to the run position, no blast of fuel. The pump is not feeding the engine fuel. Looking at the diagrams, I see there is a difference in the two harnesses. BINGO!

I'll hotwire that sumbitch if I have to! Unfortunately, this is a returnless fuel system, no regulator, one line. If you just went WTF? welcome to my world. I've never worked on a system like that. I must assume that there is some sensor in the rail that feeds info to the computer which turns the pump on and off to maintain pressure. Guess I better fire up Google an get my learn on.

[themadscientist]

Pin 27!

Pin 6 on the body harness goes from the computer to the fuel pump relay on the Hijet.

Pin 6 on the body harness of the Atrai also goes to the fuel pump relay on that vehicle, BUT only on keyless entry models. For keyed models of Atrai pin 27 is used for that. The two pins on the Atrai are hooked together, yes, so they signal should be hot on both, but since there is no keyless system on my truck, the computer is not getting the signal to energize either pin. I am out of daylight so first thing tomorrow I will carefully pull pin 6 out of the plug and reinstall it in the spot for pin 27, say a little "holy crap, I'm tired, just start you f***" prayer and turn the key.

[Gold Digger]

Just got caught up with this thread. LOVE IT!!!

[themadscientist]

I was right. I had to do some more wiring, but that was why the pump wasn't energizing. I found the last piece I needed to get the cooling system completed as well. I crossed my fingers and turned the key.



I must say, I feel like 1000lbs has been lifted off my shoulders. I really need my little truck and the past couple of weeks have sucked! There is still a lot of work still to do, but to hear it run again gets me so pumped up I have my second wind to get the exhaust modified, the BOV welded on and the AC pump situation taken care of. I will be driving it close to home and beating on it trying to make anything that is not properly done fail so I can redo it better.

Just cruising around the neighborhood was motivating. I don't have the air induction system done so the turbo is wide open in the front and no exhaust so the spinning turbine blades are half an inch from the outside air. this combines to make a unique sound.



Since Igor did actually die, and owing to his new wail of anguish I think he has earned a new name. I shall call it Banshee.

[Razi]

Long live the Banshee!

[dre1507]

I know a guy here in FL with about 3 of these. He uses them to haul around the engines he buys and sells, and parts in general.

[themadscientist]

I just got back from a short spin around the neighborhood. The Blitz blow off valve is not even thinking about opening. On the shift I think it hear it laughing at the little turbo. I will have to try finding and putting in a weaker spring. I can't have the turbo surging like it does. It sounds like a F14 powering up to launch off an aircraft carrier on the decel and then a big "POP!"

Oil continues to appear at the bottom of the engine. This engine was coated with oil when I got it and I never did figure out where it all came from. I replaced every seal I could think of before I threw it in. This could just be oil I didn't wipe off working its way to the bottom, or I may still have a leak somewhere. I'll have to watch it. Crossed-fingers, the cooling system is showing normal operating temps and there appear to be no leaks.

[dre1507]

Hopefully everything is alright with the engine, and you can continue to enjoy it. We'd love to see some videos of it doing its thing.

[float_6969]

Long live Banshee! LOL, glad to hear you have transportation again Mike

[themadscientist]

Alright, I switched out the turbo outlet and bolted the stump of the exhaust on. I salvaged an O2 sensor off the old engine and cinched up the turbo heat shield. The transmission is topped off and I cleaned the bottom of the engine up. I took it for a drive and wound it out to 6K several times up and down the road. I don't think the top speed is going to improve much, but the torque is noticeably stronger!

After I did a few runs I pulled over and stuck my head under the truck. The cooling system is holding tight, but holy s***! The oil leak is there. The bottom of the engine is basted like a turkey!

I limped it home and wiped it down and let it run in the driveway. I revved it a couple of times and I don't see a leak. I would expect this means the leak requires sustained pressure. There is an oil block that houses the turbo oiling feeds bolted where there is nothing on the other engine, The filter just screws on with the NA engine. I'm going to take an educated guess that there is a leak where this piece bolts onto the turbo engine.

I took a look at the old engine since I had a little time. This motor was spitting and coughing like two cylinders were dead. It seemed weird that it would keep spinning if something that catastrophic occurred, though.

I had noticed earlier several big cracks in the exhaust manifold and wondered if that was the problem.




I popped the valve cover off. Look at how clean that engine is! I bet dollars to doughnuts if I pop that head off I will find no damage at all. I did this whole thing because of a cracked manifold.



Oh well, it's done now, it runs and I don't think this oil leak is something I can't diagnose and fix. I mounted the gauges I have and the boost controller. I still need to wire up the sensors and plumb the controller hoses.

[Razi]

Nice knob.
The rust on the manifold makes me cringe.

[themadscientist]

So did you get the main seal out?
Yes.
Is it damaged?
No.
Strange. Compare it to the new one. What do you see?
It's bigger than the new one.
Interesting. Didn't you say they gave you two different seals last time?
Yes, I had no body numbers and they said there were two so I grabbed both.
Did they give you two this time?
No, I had the body number this time. They only gave me one.
Ah, do you have the one you didn't use before?
Yes.
Is it the same one as the one you got today?
CRAP! Yes.
What made you use the other one before?
It was the same size as the one I pulled out.
The one that was leaking just like the one you just pulled out?
Yes.
You said it only leaks under pressure?
Yes.
Does it leak now?
No.
Do you know why?
Because whoever did the seal the last time put the wrong one in there.
And what makes you different from him?
I didn't throw away a whole van because of a mistake on a $6 part.
How do you feel now?
AWESOME!

[Razi]

Yay for no leaks!

[themadscientist]

The turbo dump leaks now because I moved it to replace another o-ring I thought it might have been, but that's an easy fix.

[Dattebayo]

Sucks that you have to use body numbers in Japan.

[OriginalWheelman]

Wiring is easy if you take your time and be careful. Circuits are just like pipes. They have starts, ends, and flow. They need good connections, and non-corroded pathways. Just follow the pinouts and diagrams, and make it all line up.

[themadscientist]

I use that analogy when explaining it to non-mechanical people. Water pipes is a great way to explain electric theory too like volts vs amps and paths of least resistance and why you don't want to be that path.