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SDS Install Complete (sort of)

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Old 03-13-2002, 04:49 PM
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Russ Murphy
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Post SDS Install Complete (sort of)

3/8/02 - The SDS is all installed and wired now. I turned on the key and nothing smoked! The readout on the SDS lcd showed the sensors working - ET 68 degrees F, MAN PRES -1.42 inches of mercury. Pretty neat. My wiring of the KLR worked apparently, as the factory boost gauge read slightly less than 1 bar. The big/giant intake is done. All I need now is the balance belt pulley back
from my friend Alan(machinist). The waiting is driving me nuts! I should have pictures in a couple of days.

3/13/02 - Well, belts and alternator and a/c delete bracket and cam tower and distributor and intake manifold and new intake are all installed.
Time to fire it up! No start. The SDS LCD screen says magnet not seen. I reposition the hall sensor slightly and voila, magnet seen. Still no start. Check spark, got spark but you know I haven't heard the fuel pump. I look at Danno's schematic and find a black/grey wire that runs to the DME relay and complete the circuit and now we've got fuel. I crank it again while turning the mixture **** and it starts but revs up kinda high.
Whoops, I forgot to plug the idle bypass fitting in the manifold. Plug it and restart. Let it warm up before screwing with the rpm fuel values and watch all the smoke come off the exhaust. I adjusted the rpm values once warm using the AFM and thats about as far as I got last night. The motor is really smooth and revvy, but the belts are really whirring. I don't know if this is normal or if something is amiss. I'm working on loading up pictures soon. I must say , it was pretty neat when it fired up.

Problems to run down: no tach signal, no thermostat control(no heat in the cabin).
Old 03-13-2002, 06:51 PM
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Konstantin
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exciting!!
keep us updaded.

Konstantin
Old 03-13-2002, 08:42 PM
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Russ Murphy
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Thanks Konstantin. I will. Unfortunately I'm leaving for a family vacation early Fri. morning and I'm afraid I won't be able to do anything else until I get back (the 25th).
Old 03-14-2002, 02:20 PM
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Russ Murphy
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Well, we went on our maiden voyage around the neighborhood. I kept it out of the boost but pulled it up gently to about 5000 rpms. Still burning oil off the manifolds. The thermostat works now, but I still have to fix the tach. It's a little scary but definitely fun.
This will be all I get to do until I'm back from vacation. <img src="graemlins/xyxwave.gif" border="0" alt="[bigbye]" />
Old 03-18-2002, 12:38 AM
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rage2
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Congrats Russ! You got it fired up a lot quicker than I did. Did my fuel/spark maps help any?
Old 03-25-2002, 07:32 PM
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Russ Murphy
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rage,
I just got back from vacation last night, hence the delay.
Yes, thank you so much. The values that SDS put in originally were what I used to start the car initially. For some reason the calculated base rpm fuel values are closer to working for my car than your rpm values and that's with the map fuel values the same as yours. Weird. I'm still trying to get the pics from my buddies digital camera. Once I do I'll put together a semi-detailed synopsis of the project. I still have to finalize the rpm fuel values via WOT with no boost (I'm going to leave the blow-off valve off) and then I might get to put a little foot into it.
Old 04-04-2002, 11:21 AM
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Russ Murphy
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Well,
Sorry for the delay, I’ve tried to post this thing two different times but it wouldn’t "take".
To back up a bit here’s a list of all the stuff that came out of the car: air flow meter/j-boot/filter box/snorkel, ac compressor/bracket, cycling valve/tubing/hoses/bracket, most tf the crankcase ventilation stuff, cruise control motor/cable&housing. These deletions opened up a lot of room, especially at the back of the motor where lots of things want to occupy the same space (cycling valve/head coolant fiting&hose/vacuum lines/temp switch/wiring harness.

I built an intake out of silicon reducer pieces and a 3" elbow with short steel tubing splices.
My buddy Alan did a great job with the hall sensor bracket. He said he’d make more if any of you opt for SDS.
I ran Purocil from the MBC to the banjo bolt and the sensor wires got aluminized fiberglass tape covering.
I mounted the MAP sensor and injector resistor board on the firewall in the space freed-up by the cruise control deletion.
So the engine bay ends up looking like this.
The SDS computer went where the DME used to live with only a minor rat’s nest of wiring.
Old 04-04-2002, 11:44 AM
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Russ Murphy
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And I stole rage’s idea and mounted the SDS afm where the clock used to live. The MBC occupies the cigarette lighter hole.

The tuning is going well considering I only have the slightest idea of what I'm doing. Many thanks to rage for his SDS fuel/timing values and to Danno for his DME/KLR schematics and pin-outs.
I ran the car initially with out the compressor bypass removed so it functioned as a normally aspirated engine. This took the wildly fluctuating map out of the equation for the initial rpm/fuel tuning. I worked on that until I got a nice smooth pull at WOT. Then I reinstalled the bypass valve and lo and behold I had the MBC hoooked up incorrectly for the stock(single port) wastegate.
Once I fixed that then I stared to work on the map/fuel and map/timing values. I was getting a little preignition that the knock sensor feature wasn't correcting. Turns out the bosch knock sensor is picky about polarity. DOH! That's fixed now, so things are a little less nerve wracking. So what's the verdict? It's a little to early to say but when I shift gently into 2nd and then roll into the throttle all the way The smoke doesn't stop until I do and that's NEVER happened before. And that's at 7-9psi! Holy Cr#p! I have a new found respect for the monsters that Paul/rage/Konstantin (or anyone else with 300+ rwhp) have.
Well thanks for reading. Here's a few more pics.
Cheers. <img src="graemlins/beerchug.gif" border="0" alt="[cheers]" />





Old 04-04-2002, 01:47 PM
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rage2
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[quote]Originally posted by Russ Murphy:
<strong>And I stole rage’s idea and mounted the SDS afm where the clock used to live. The MBC occupies the cigarette lighter hole.</strong><hr></blockquote>

Actually, it's Danno's idea. I stole it off his web site =).

[quote]Originally posted by Russ Murphy:
<strong>So what's the verdict? It's a little to early to say but when I shift gently into 2nd and then roll into the throttle all the way The smoke doesn't stop until I do and that's NEVER happened before. And that's at 7-9psi! Holy Cr#p! I have a new found respect for the monsters that Paul/rage/Konstantin (or anyone else with 300+ rwhp) have.</strong><hr></blockquote>

You'll get used to it soon and ask for more. I'm itchin' for another 200hp... wonder where I can find that...
Old 04-04-2002, 04:04 PM
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Danno
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"when I shift gently into 2nd and then roll into the throttle all the way The smoke doesn't stop until I do and that's NEVER happened before. "

I assume you mean TIRE-SMOKE right? Wow, that's incredible!
Old 04-04-2002, 05:20 PM
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Russ Murphy
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Yes Danno, wheelspin not blown head gasket! I might have gotten a little caught up in the moment while I was composing. I should say the wheelspin
doesn't stop. There's just a little smoke.
Old 04-04-2002, 06:58 PM
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OZ951
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Russ, great post - thanks for the info and pics. I think its always good to describe what goes wrong during the installation and test as well as what goes right.

How much will one of those hall sensor mounting brackets cost me from your machinist mate ? (and how long before he can deliver ?)

Cheers,
Wayne.
Old 04-04-2002, 07:52 PM
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Russ Murphy
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Thanks Wayne,
I don't really know how much, but I'll ask. Alan has to wrangle time and access to machines to do it, but maybe I'll have him do a handful and pay him for them and then just dole them out if someone wants one. I'll check on the timeframe.
Russ
Old 04-05-2002, 09:16 PM
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michael2e
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Russ, thanks for all the detail on a great post. Congratulations... "Holy cr*p" gets the message across! How did you mount the sensor bracket? BTW I'm looking for an A/C compressor if you're interested in parting with it.

Mike
Old 04-06-2002, 01:04 PM
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Russ Murphy
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Thanks Michael,
The sensor is bolted to the motor with two of the front seal/cover/thing bolts. I don't know what you call the cirular aluminum piece that surrounds the crank on the front of the motor held on by 8 or so bolts.

I'm afraid that the compressor is gone already. Sorry. I still have a DME, airflow meter, cruise control motor/acuator and one of the flywheel sensors (the other one broke ).


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