I have lost count of the number of times I checked the pinouts for the ECU and it turns out all the hard work payed off (with one minor adjustment I'll explain later).
I'd done all of my pre flight checks, the warning lights on the dash have been completed and the ECU turns on:
After a trip to the garage for some fuel it was time to turn the key and see if she starts. Very nerve wracking, will it work or will there be a puff of smoke? After checking my fire extinguisher was in reaching distance and wheeling the car out of the garage I turned the key to position 2 - fuel pump whirred into action, turning one more time the car tried to start. Great - at least the starter motor works! And.....nothing....not even a splutter. Tried a couple more times and gave up, something was wrong.
Turns out the first check I did was the right one - do we have fuel at the rail? Nope. The high pressure pump was fine, but, nothing coming though. Checked the low pressure pump and....dead! I had the earth cable the wrong way round (!!!). Fixed...but still nothing.
After a few hours and RTFM it turns out the ECU will display a red light on power and a green light on crank - I only had a red light, no change during crank. The engine RPM was also 0, meaning the crank position sensor wasn't giving the ECU a reading. Time to go to bed and have a think.
Day two came and I did further reading and took the decision to cut off my nice and neat 2 pin junior connector and replace them with some spades, this allowed me to switch the pins round.
Great. I went to give her another go and caught a hint of petrol, after checking it seems like the high pressure fuel pump was leaking! After literally two hours of messing around eventually I took the whole thing out and wrapped some PTFE tape around the inlet - apparently I had missed it! Leak sealed, petrol mopped up.....turned the key and...success!
There was a small leak coming from the temperature sensor so knocked the ignition off and....nothing....car didn't switch off!?! After a mild panic I remembered I had decided not to tighten the battery terminals as pulled the negative lead off - that was the right decision.
Another couple of hours of head scratching and reading the Emerald manual I decided to connect both pins 11 and pins 28 together. The ECU has pin number 11 attached to the ignition switch, giving a 12v switch supply, but it also receives power from the main relay (which powers the injectors, IACV etc). It effectively has two supplies and it should sense when pin 11 loses power ("key off") and turn itself off - it didn't, that's one way of providing power to the ECU. The other is to connect both 28 and 11 together to the switched supply - bingo! Car now starts and stops :)
List of things to do:
- Inspect low pressure fuel pump - it is weeping fuel, I suspect its the same issue as the high pressure pump. PTFE is safe to use with fuel so I will re-fit with some on
- Check fog light wiring - it blew a fuse when turned on
- Check alternator wiring and charge - I don't think it is charging the battery, earth looks good but voltage at battery seems low (from memory it should be ~14v when engine running, but that could be wrong)
- Adjust clutch - it will not engage, cable is lose.
- Adjust wiring documentation to reflect pin changes
- And more....
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