flameredturbo

I'm rewiring that part at the moment, I'll double check it's only live while I push the button.

I took the sensor of yesterday it looks as good as new seeing as it is I guess. Thanks for all your help.

I've taken it all apart and the starter is boxed up ready to be exchanged as it was making it's own nasty sounds.

Waiting on some new wires and a new pressure reg so it's in bits. It sounds as if you are hitting the bell-housing with a hammer.

Jealous!

Yup, retroford 1.8 zetec, drilled to take pinto clutch, starter is lrs707.

Just a thought the starter solenoid is operating correctly? If you have a bad engine earth or poor supply these can click in and out, and they go with a clunk?

I'm hoping it is something along these lines, the clunk was definitely the flywheel and starter cog as the old starter mounts where broken from it happening.

Also I'm not familiar with omen but on the emerald ecu you have to tell it what crank trigger you are using and what tooth pattern the flywheel is. I think the Zetec is 36-1, is this setting correct on the omex software?

I confirmed with omex that the map is correct for the flywheel. I did think after though if it was possible to calibrate the sensor, as in set tdc or something like that.

We did discover some shocking electrics today though, if the ecu had an irregular switched charge/lost power mid crank would that cause these clunks??

Baffling really!

The loom is made by Harnessing solutions, I've checked and double checked the leads are correct. It's a brand new coil also. It has also run.

The spigot bearing is in also.

That's what we checked today, didn't do a compression test as I guess there was no need. The mechanical timing was all good.

The guy I spoke to at omex on Friday did say that kickback shouldn't damage the engine.

I'm going to get a fresh map from them or a known good one before I try again. Few odd jobs to do before then though.

Timing is correct, so that rules out mechanical timing causing issues.

After ripping apart the loom further today and discovering other horrors ontop of the one blue had discovered I'm hoping there's a chance that my problems are down to electrical gremlins.

One of the problems was that the loom seemed to be made with two + feeds for the starter or they where at least wrapped together so my brother wrongly assumed one was an earth and wired it up to the neg to earth it!

The other problem I think was being caused by my fan relay which isn't used but still had a feed on my switched ignition, the same part of the loom I was using to feed the omex switched +.

My only worry now is it may have caused damage to the crank bearing with all this clunking I've been having! There was a nasty noise that I'm fairy sure only happened while the starter was cranking but I'll not rest easy until I'm sure!

All just sounds like adjustment. Where in London are you?

wouldnt be the first time a crate engine hasnt been built and timed up correcly

I've got the loan of a timing kit so I'll soon know, how far out causes damage?

Has the cam belt jumped a tooth on the cogs ?

 

Stephen

I'll be checking when I steal johns timing kit.

Another random and probably wrong idea.

 

Clunking starter and failing crank signal. Is the flywheel fully fastened up and not wobbling about?

 

As I said, random and probably wrong....

This was a concern at first I must admit but I torqued it on with new bolts and when it's run and cranked over and over it doesn't wobble or clunk.

Omex 600 does not run using eddis it controls spark it self and timing.

 

can you plug a lap top in to omex and check signals

 

Having a knock on the crank sensor sound likely get a new sensor / from scrap yard and try that /

 

or first unbolt it to see if it looks damaged. also could be damaged to fly wheel from starter.

 

Stephen

I'll take it off and check, I might even be able to lay my hands on another to test it.

the crank and flywheel sensor are one and same is the cable shielded cos for the megajolt it had to be sheilded

Was a custom loom made for the ecu so I assume it's as it needs to be.

Which omex are you running?

 

Have you checked the base timing? I.e with a timing light while the engine is cranking over by and pulling the fuel pump fuse/relay

 

Tb balance makes a massive difference to how smoothly things run. I have had mine popping and banging back out the manifold and running like a dream after setting the balance.

Not checked anything with a timing light no, it's a crate lump so assumed the timing is correct, I will be burrowing a timing kit to check though.

Google confirms omex does the eddis job so no need. The crank position is detecting the crank or I'd not have spark and fuel etc. I assume the crank sensor controls the timing?

The flywheel can only go on one way? The 1.8 fly has the same position markers as the standard 2.0?

Just a random thought. As you've been messing about with the starter have you bashed the crank sensor (the thing just above the starter pointing at the fly wheel) and broke a connection or maybe not got it plugged in?

That has just occurred to me, had just pm'd join thinking the same, it's almost as if it's sparking on an upstroke.

As above though, the engine has run, and does rev up when you get it running.

Edis looks like this

http://www.ebay.co.uk/itm/ford-fiesta-rs-turbo-edis4-zvh-escort-zetec-turbo-KIT-CAR-/131146066910?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item1e88ea2bde

I don't have eddis then.

the only ignition system I have heard of which does not use the eddis is nodiz

Is it built into the coil pack? Have I missed something?

I see, I don't have eddis. Omex was showing a timing alignment of 0.3516 and a target timing of 1.99 I think, I can't fully remember, blue might. These are figures from a map direct from omex.

What's eddis? With the coil pack unplugged I'd not have had any spark atall.

Fuel doesn't soak up does it so must be air!

As many of you will know I've had plenty of teething problems, that's continued today.

Thought I had the starter clunk issue sorted with a new one, how wrong I was! However.... It still clunks but only when the ECU is connected, or more so the coil pack. So a ignition timing issue? The leads are all correctly plugged in the correct places, the most confusing thing of all is it has run!!!! Not very smoothly but it's run none the less!

Also to say my inlet manifold isn't flat would be an understatement! Maybe upto 1mm out with two different flat edges to check. Pic shows the gasket, I thought that was a clear sign of an air leak but maybe it's just where fuel has soaked down? What do you think?

All help gratefully received, quite a low point!

Also huge thank to Lewis (blue) for his help today!!