another Alfa Romeo conversion

[festy]

Fuel pressure regulator on it's way (little brothers are handy), and my VR coil pack arrived today.
I think I have all the bits and pieces I need to be able to start it up now... once I finish putting it all together that is.

I started fitting the wiring harness today, and have a temporary fuel rail clamp setup that will do until I can get hold of the correct bolts.

One issue I noticed was that the Pulsar being an EW engine, the MAP sensor harness plug is on the wrong side of my engine bay
Is there any reason why I can't run a long vac line across to it? Or should I extend the harness wires and mount the MAP sensor close to the plenum?
A long vac line is easier, but will 2 feet extra of hose dempen/delay the reading?

And can anyone tell me if the large port on the top of a v6 throttle body is the vac line for the brake booster? If not, my plenum needs another modification

vac1.jpg (45.45 KiB) Viewed 5191 times

[Holden202T]

that large fitting in the picture is where the PCV normally connects to, for the brake booster just put a fitting into the plenum somewhere

i haven't really had any experience with longer map sensor hose but i wouldn't think it would be an issue.

[festy]

that large fitting in the picture is where the PCV normally connects to

That would make sense I suppose, considering it's on the wrong side of the throttle plate for a vac line

[Holden202T]

[blownvp]

just use thick wall silicone hose for map sensor.

[festy]

I got a chance to test my fuel rail under pressure, and the good news is that my injector hats didn't leak like I was expecting them to!
That may be because the rail never got up to pressure due to a pinhole leak in one of my end cap welds, and my hastily-made adapter for the FPR didn't seal too well - I need to tap the 3/8npt thread a little deeper.
I'll fix those leaks up and try again...

[BradGTV]

what diamter is your crank trigger wheel going to be? does anyone know if the diamter of it can be changed or does it need to be the exact same size as the lada one? cheers, brad

[antus]

Yeah it can be changed, just needs to be to scale.

[festy]

Today I wired up the fuel pumps, plumbed enough temporary lines to test and tried to prime the fuel system...
Couldn't work out why fuel wasn't making it up to the rail, so started working backwards, even thought I might have had the pump wired up backwards, but couldn't get it to prime.
I ended up taking the overflow hose off the surge tank and blowing into it while the pump was running, that was enough to clear the air pocket, and it primed.
Quickly reassembled everything I'd taken apart, and got the fuel rail up to pressure.
Then I noticed smoke coming from the front injector
It turned out to not be smoke, but fuel being atomized as it escaped from a pinhole in one of the injector boss welds
I had a good look around while it was up to pressure, and found another leaky weld at the FPR end of the rail - so now I have to take it all apart again, clean the rail out, cut back the two dodgy welds and re-weld, then do it all again
This isn't fun anymore
One good thing to come out of it, I at least know that my injector bosses seal well enough to keep pressure in.

[Holden202T]

thats one thing i like about welding with OXY is you can flow the welds to sort out issues like that easily, but this is working with a steel rail and i've oxy welded alloy before ... and NEVER AGAIN!