The Roadster NA Journey Begins

[Tim_cyc03]

http://www.aftermarketindustries.com.au ... -kit-sp400

or

http://www.radiumauto.com/MPFST-Multi-P ... -P271.aspx

Stock or your 255 as the lift pump, and there will be no issues.

I've got a 460 or what ever it is walbro in my surge tank.

[Magpie]

Stock or your 255 as the lift pump, and there will be no issues.
I've got a 460 or what ever it is walbro in my surge tank.

Thanks, been looking at them...

Since my car is not boosted there is no need for the fuel pressure to be increased to compensate for increased manifold pressure, hence need to maintain a constant FP.

Injector Dynamics site injector calculations suggests that at 8,500 RPM my ID 725's should be at about 68% duty cycle and need 107.75 ltrs/hr of E85. Looking at the data on the Walbro 255 I have it should be able to, at 12v flow 223 ltrs/hr at 40 PSI. If the voltage increases to 13.5 then it is 265 at 40. The calcs of duty cycle are similar to what the car gets in real life.

This leads me to another train of thought, that is there is a voltage drop at the fuel pump as load increases. IF, the problem is still there after this weekend then I will have to look at the wiring and the FPR.

[Magpie]

Car back together, of the 4 injectors 2 had flow that were 4.6% and 2.3% less than optimal. The comment was that for a few years on E85 they were actually quite good

I used http://www.fuelinjectorservices.com.au/ which is a mobile service, he turned up when said he would, charged what was quoted what more could you ask!
Injector by Eipeip, on Flickr

There is very little space to work in when the bulk of the airbox is left on, however would not trade it for the world Plus I'm starting to learn more about the car

Previous actions:

1. Fuel pump pressure upped to 43.5 to match the settings in the PS1000
2. Tube put on the FPR to stop any change in the FP caused by atmospherics
3. Warning put on IQ3 for if FP goes outside 35-55 PSI
4. Engine protection activated if FP goes outside 31.5 and 55.5AND TPS is more than 25% for more than 2.5 seconds
5. Engine protected added if EGT goes above 850°c as I removed this warning from the dash to make way for the FP warning.
6. Added additional logging channels to the ECU, only have 9mins recording available but this should cross reference against the IQ3 data. The advantage of the ECU datalogings is that it can be done at a higher resolution. Have a switch to turn on/off ECU datalogging

Will be pulling the logs from the car after each run at General practice to see if everything is OK.

Plan B (in no order)

1. Drain the E85 out after each event and run some 98 through, saves the E85 sitting for a few weeks.
2. Change out FPR
3. Install surge tank (thanks for the links Tim_cyc03)
4. Install fuel filter suited to flow of the pump. There is a very slim chance that the fuel filter may not be able to handle the flow. However, the big question is why now... is it just the result of E85's long term effect?
   
   Still have some other jobs to do on the car before Saturday, work is such an inconvenience

[Magpie]

Plan B is now up, more than likely need a few more backup plans

[The American]

If the car used to run fine all the time, and runs fine early in a session, and not so well later, and you've identified that the fuel pressure is dropping, AND you've changed out the pump to eliminate it as the weak link, it makes me suspect the FPR diaphragm.

[Magpie]

it makes me suspect the FPR diaphragm.

Sounds like this could be the problem. Whilst may not be an issue the Tomei regulator is installed on its side and every picture I can find shows it mounted vertical. Again the question is why now. Will replace the FPR and then see what happens.

The Haltech engine protection works a treat, takes the decision away from the driver! Whilst I was trying to pay attention to the dash warnings, the alarms were coming up when trying to concentrate on other things. The video clearly shows the light on The ECU goes into limp once the error has been ongoing for more than 2.5 seconds, so at times I would be able to back off and let things return to 'normal' however sometimes I just did not react fast enough.

This is even more frustrating than the CAS sensor. Positive is that even with these issues I'm very close to my previous PB's!

Days events...
20170218 QR FP by Eipeip, on Flickr

Just to go to the wrong side of data collecting, ran the heart rate monitor for the sprint session.

Here is the info when the ECU went into limp mode, spike of 130bpm. It went into limp just before the dipper so I went down the back straight.
FP Loss by Eipeip, on Flickr

The only other time I got that excited was going to the toilet between sessions
Toilet by Eipeip, on Flickr

[Magpie]

Plan of attack for the fuel pressure issue:

1. Confirm wiring to pump is adequate and no issues.
2. Check all the fuel lines to ensure no kinks, may take the opportunity to replace some as well to ensure the E85 has done 'nothing' to them.
3. Test - possibly Norwell/Paul Stockell Driving Events

Backup plan - test QR 16/02/17 (Time Attack Round 1)

1. Replace fuel pressure regulator
2. Install surge tank
3. Park the car up and call 2017 off

Looking at http://www.radiumauto.com/FST-R-Fuel-Surge-Tank-with-Integrated-FPR-P348.aspx. This saves on fuel plumbing as the system becomes a returnless dead-end system and every thing on the unit can be rebuilt (including the regulator).

[Magpie]

Spanner in the works, back to working in NZ for most of March. May have to just do a 'single' fix and hope one of these actions fixes the issue.

[3gress]

Hi mate, irrelevant to current topic (my money's on fpr diaphragm failure ), how did the 'glass front fenders go? Any plans to fit them up or such? Are class regs' holding you back from installing them?

[Magpie]

Hi mate, irrelevant to current topic (my money's on fpr diaphragm failure ), how did the 'glass front fenders go? Any plans to fit them up or such? Are class regs' holding you back from installing them?

Agree on FPR being the offender...

Glass fenders are 1 kg lighter, however WTAC rules require OEM fenders. However they can be modifier with flares to fit tyres. I doubt that they will accept that the glass fenders are just BIG flares.

Plan is to fit them up soon, have them painted and fitted. I can always take the OEM down just in case

Also have to make the Jetstream headlights look like OEM. Clubsprint rules require OEM & working headlights. I should be able to keep the Jetstream ones, just put some Perspex covers on them and have them painted to look OEM. To have working headlights I just take the covers off...

[Magpie]

Surge tank arrived this morning, 7 days from the US. Many thanks to Troy from http://www.prospeedracing.com.au/ for keeping me informed of where it was. Was shell shocked when it left their shop at around 1200 on 01/03 and was on my door step at 0900 on 02/03!

Why this model, well because it has an inbuilt FPR that is fully serviceable and lets face it different. Very few things on the car are what would be considered 'normal'. Whilst it is debateable that the car really needs a surge tank, time has been my enemy to get the car ready for Morgan Park when I will be overseas for most of March and have limited time to 'test' other potential fixes.

This surge tank requires that the fuel system be changed to a dead end, since this has now been done it should be an easy install. The benefit of this should be that hot fuel should not be returned to the tank.

The package
DSCN4083 by Eipeip, on Flickr

Nicely packaged
DSCN4084 by Eipeip, on Flickr

The surge tank (about 1.5 ltrs)
DSCN4085 by Eipeip, on Flickr

The whole package
DSCN4087 by Eipeip, on Flickr

The built in FPR
DSCN4088 by Eipeip, on Flickr

Pump installed (Walbro 460 E85)
DSCN4090 by Eipeip, on Flickr

Instructions say that the filter sock is optional so will confirm with Pro Speed that this is correct
DSCN4092 by Eipeip, on Flickr

Almost ready to be installed on Saturday. Need the bulkhead connectors to turn up
DSCN4094 by Eipeip, on Flickr

[speed]

Surge tank and associated bits look good. Suspect that the sock is optional as you already have a sock on the pump in the fuel tank. If the 2nd sock doesn't disrupt the pressure you need than it can't hurt but at the same time could be an extra serviceable item.

Sent from my GT-I9506 using Tapatalk

[Magpie]

Speed I agree on the sock being optional, yes the tank pump has a sock, plus there is a 100 micro filter being installed from the tank to the surge. I do have the option of keeping the OEM filter in place or putting a 30 micron filter after the surge and before the rail.

[3gress]

Hope this link works, it is a fuel pressure sensor that i have connected just before the tee fitting feeding the fuel rail in attached picture. The sensor is hooked up to my autometer gauge but you could integrate it into your logging setup. It will allow you to monitor pressure at fuel rail end of plumbing.

http://www.autometer.com/100-psi-pressu ... ducer.html



You can see the teed fuel line running to both ends of the fuel rail. The pressure sensor fits in just below the tee on the single feed line.
Disregard the trackdog rotrex bracket, that is a dream for another day....unless you wanted to swap me your auto+ aiirbox for it

Edit: ok so the autometer pressure sensor link didn't work but the part no.# for sensor is AU2246 and i received it along with the autometer cobalt 2-1/16" full sweep cobalt fuel pressure gauge.

[Magpie]

3gress your information to date has been very helpful, many thanks

At the moment I have moved the pressure sensor to the end of the fuel rail. I have no plans to add a T into the rail.

Just in case you have not seen the Plus air box before here is another shot of it (plus the fuel sensor in the background). One of the sad parts of the air box is K&N have discontinued the filter that the air box was designed around. So the hunt is on to locate some spare filters...

DSCN4068 by Eipeip, on Flickr