Hi guys.
I am having an issue with a 4G63BT running a Wolf ECU that is doing my head in so I am hoping someone with more experience than I might be able to help me out. There is a bit of a story here so please bare with me.
I have a Lotus 7 replica with a bit of a 4G63 bitsa engine, due to the fact it is rear wheel drive it is using a Starion block (and gearbox) but running an Evo 3 head and is also running a Wolf 3D V4.57 ECU. I had a lot of dramas with traction (funny about that) so decided to take the car off the road so I could cut the rear guards and widen them to get some 10" tyres on the back. Unfortunately this then turned into making an entire new fiberglass body based on a Leman car which had the 7 off the road for about 7 years. I then bought another 7 replica and have started yet another project so decided to remove the half finished Leman body and get the turbo 7 back on the road. During the process of putting it back together I did the following:
- Replaced the high pressure fuel pump (the old one had seized)
- New fuel lines & filters
- New vacuum lines
- Replaced the timing belt
- Replace engine temperature sensor which was a dud
- The usual oil, filters, plugs, etc
I also made an entire new wiring harness for the car from scratch (I work in the auto electrical industry) which included re-wiring the Wolf ECU. When I was making the harness I noticed that the injectors were wired in batch configuration rather than sequential so I figured there must have been a reason for it and thought I'd better double check as I figured you could get a more accurate and fuel efficient tune using a sequential set-up. So I rang Robbie at Wolf Motorsport and asked him which way it should be set up to which he replied sequential would be the better option, I said oki doki I will wire it as sequential instead but I assume that would mean it would need to be re-tuned and he confirmed it would. So I put the whole car back together and rang Robbie so he could walk me through the engine configuration set up in the software so I could start it in a sequential set up. Anyways, since there is no-one in town who has a clue about tuning I thought I would run it back in batch configuration via the software and re-load the tune that it last had before I took it off the road and it should be running the same way it used to. I could then drive it to a decent tuner (300kms away) and they could change it back into sequential mode in the software and re-tune it to suit. No such luck, it is running like a complete dog and fouling plugs and the ECU seems to be triggering in an odd pattern. After a couple more phone calls to Robbie (who I hate to hassle because he is a busy man) it turns out that due to the trigger disc it is running it could only running in batch fire & wasted spark mode anyway! No dramas, I will just put it back the way it was but it just isn't running right. So I have done / checked the following:
- Checked all vacuum lines which are new and all good, even pressurised the system up to 15PSI, no leaks.
- Recalibrated the new temp sensor in the software but the calibration chart is nearly exactly the same as the one already loaded in the tune as I used the same model sensor.
- Injectors were cleaned and flow tested before refitting.
- Vacuum on the Wolf handset (built in MAP sensor) reads the same as the boost gauge in the dash.
- Engine and air temp sensors have been tested and read the same as the dash gauges.
- Checked the cam timing markers line up, did this three times and the tensioner is fine and within spec.
- Triple checked all the wiring for the ECU is going to the right sensors, power and earth are all ok as is the shielded cable coming from the CAS which I have also replaced and ran a whole new cable outside the car away from any potential interference.
- Checked the trigger input from the CAS with an oscilloscope and there doesn’t seem to be any noise on the input.
- Checked the igniters which seem fine as does the 13.8V they are getting.
- Swapped out the plug leads even though they measured fine.
- Swapped out the coil packs even though the old ones and the replacement ones both measure within spec on the primary and secondary coils.
Checked the fuel pressure which was 44 PSI with the vacuum line connected and 53 PSI disconnected. No fuel out of the regulator vacuum port so diaphragm seems ok.
I believe it has something to do with the ECU setup stuff but don’t know enough about the pulse offsets, etc, so was hoping that someone else out there might be running a Wolf ECU on a 4G63 in batch fire mode with wasted spark and using a 4+2 trigger input.
The trigger disc looks kind of like this and obviously used to work before I took the car off the road:
Trigger sequencing:
Injector sequencing which has since been change to the following since the injectors are wired in cylinder order not firing order. I have also tried changing the injector pulse skips all to 1.
Injector 1 Pulse Offset - 0
Injector 2 Pulse Offset - 1
Injector 3 Pulse Offset - 1
Injector 4 Pulse Offset - 0
Ignition sequencing:
Since only ignition 1 & 2 outputs are being used with output 2 running the dual output coil for cylinders 1 & 4 and output 1 running the dual output coil for cylinders 2 & 3 I have changed to be the following to be:
Ignition 1 Pulse Offset - 1
Ignition 2 Pulse Offset - 0
Ignition 3 Pulse Offset - 255
Ignition 4 Pulse Offset - 255
Ignition 5 Pulse Offset - 255
Ignition 6 Pulse Offset - 255
Nothing seems to be helping. It is running extremely rich and fouling plugs (I have tried using the fuel trim to cut it back but it helps a bit and then dies while still blowing black smoke).
What worries me is that the timing marker bounces between 0 degrees and about 8 degrees BTDC when I set the ECU to 0 degrees and crank it over (injectors and coils unplugged). The ECU firing is erratic, here is a vid of the outputs slowed down with the ECU on my test bench and running the CAS with a drill at constant speed: http://vid32.photobu...zpsttnz6afx.mp4
Please Help!!!
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