2002 Lotus Esprit V8 TT build

[marktc]

Re: 2002 Lotus Esprit V8 TT build

Thanks!!! So, I only have 2 sensors left to wire in for the basic setup. I finished the CAM position sensor yesterday -- major pita due to the location of the wires being in the area of the back of the engine, between the block and the intercooler piping. I extended the wires slightly so that I could solder into the new sheilded wire easily. I guess this means that I will have to shield as much as I can on the wire extensions as well. Tonight, I will likely finish the Air intake temp sensor wiring and, if there's daylight enough.. the Crank Angle Sensor.

[marktc]

Re: 2002 Lotus Esprit V8 TT build

Last 2 sensors hooked up... now for the really fun part -- getting it to start!

[marktc]

Re: 2002 Lotus Esprit V8 TT build

Well... I've gotten most of the way to starting the car.. I had to adjust a few ignition trigger sensor settings in order to get the car to register an rpm signal and finally start to fire the plugs. Now it's flooded though.. lol. I will pull the plugs friday and add a little oil to the cylinders. Then, double check my ignition timing and start adding fuel to the mix again.. So far though... every wire is correctly done!! WOOT!

[RONDAL]

Re: 2002 Lotus Esprit V8 TT build

This is awesome

[marktc]

Re: 2002 Lotus Esprit V8 TT build

So, the next step is to figure out what the engine timing is with respect to the signal from the reluctor-type crank angle sensor. The factory harmonic balancer/pulley does not have any timing marks on it however.. so this poses a bit of an issue. First thing I need is a pointer of sorts that I can attach and see where the timing marks should be made. Now, since I need to do a couple of timing belts at the moment anyway, I thought I should do a dual-purpose marker. So.. I pulled an old aluminum ruler off of the wall and started:


I cut the end off..




Then used a 13mm socket to make a nice scribe of a circle that will fit properly:




Get the vertical sander ready...




Here is the end finished..




Then I drilled a 5/16" hole in the end.




Then... sanded out a notch and an angle-type marker:




Then.. Install it so that the bends can be done properly and that it has a fine clearance from the harmonic balancer:




And heres the final shot of the side profile with the bends complete:

[CGDoig]

Re: 2002 Lotus Esprit V8 TT build

This is the first I've read of this. Best build thread on here in a while. Keep it up.

[marktc]

Re: 2002 Lotus Esprit V8 TT build

Thanks guys!! This weekend will likely result in less work on the standalone.. and more work doing the timing belts and other maintenance items on two of the other esprits... but I should be back up and running on the build by monday.

[marktc]

Re: 2002 Lotus Esprit V8 TT build

So, I tried a few times to get Johns car to run as it sits, however, I learned that the factory ecm has a built in ignitor. This means that I don't get any spark power. So, I baught an igniter from a 2001 Volkswagen Passat. Instructions are to apply a heat sink to the aluminum backing, so I got my friend to locate me a nice heatsink from an Asus Computer processor chip. I also found one harness in my collection of random electrical connections for the 4 pin side, but I had to order a new 5 pin connector for the input signal side.
Tonight, I built a mounting system for the new ignitor....

Here's the ignitor:


Here's the Heatsink, mounted to the ignitor:


Remember that aluminum ruler I used to make the timing marker... I used it again


Then I drilled a couple of holes in the aluminum ruler part and threaded it for a couple of small 4mm allen bolts:


Then I polished the ever living heck out of the aluminum ruler... (not as good a polisher as Chris.. but I try.)


Here it is installed...


And here's both ECU's installed with the Ignitor:


So.. next is to wire up the new harness' and VAROOOM!!!!

[marktc]

Re: 2002 Lotus Esprit V8 TT build

Well, yesterday, I managed to get some more soldering done on the car.. I simply soldered the output wires for the Ignitor. Not a lot of progress, but it's something. I will have the Widebands landing today and the new injectors. I'm still missing one plug, which should land on monday.

[marktc]

Re: 2002 Lotus Esprit V8 TT build

Today.. I have achieved... SPARK!!! WOOT! Now all that's left is the total PITA that is getting the fueling right to start it...

[marktc]

Re: 2002 Lotus Esprit V8 TT build

So, Today was a huge day.. we put the intake plenum back on the 2000 esprit and took it off the jack stands. We also did a boatload to the black 2002 -- Transmission back together, decklid back on, replaced brake pads, changed oil and a few other little things. Then.. we tackled the stand-alone..


For quite a while, we tried to get it to run.. and no luck. Turned out the fuel pump relay wasn't activating. So I bypassed it completely and turned the car over and VROOOM!!!!! WOOHOO!! However, I still couldn't get the ecm to activate the relay. We checked the impulse signal from the ecm.. it was working, we checked to see if I just hotwired the relay if it worked.. and it did. So I called a tech and he said he never activated the fuel relay from the positive signal. So, I eliminated the rollover sensor and used that wire to be the active ground for the ecm. And, finally we had functional fuel pump relay!!! So.. next.. we had to install wideband o2 sensors. We relocated the factory ECM wideband sensors to the back (where the secondary's should be) and put the new widebands in their place. We then ran wires from there into the cabin of the car, behind the carpet on the passengers side. We also temporarily placed a wideband guage on the dash and properly wired it in as well. Here's a shot of what we did to the wireing inside the car.. I will take some more shots at a later time.





And.. if this works.. here's a video of the second start up.. the car has a bit of a sticky lifter that tends to get sticky when it sits too long... so kindly ignore the "tick"

[marktc]

Re: 2002 Lotus Esprit V8 TT build

Today I yanked off the intake plenum.. part of the intercooler system and began the process of installing the massive 725cc injectors. Here's a photo log of the events:


The intake plenum.. removed (I think you've all seen this scene before)




The New injectors:




Their accesories (an injector length extender and wiring stuff)




An assembled injector:




The factory injector plug..




CHOP CHOP!




Dont forget to put on the silicone seals before you solder on the plug ends..




One piece soldered on..




Plug assembled.. and then push in those pesky silicone seals.




Do that eight times.. and then...


Here's the injectors installed..




I actually have to finish up the last four tomorrow.

[R-Audi]

Re: 2002 Lotus Esprit V8 TT build

Im sure you know your VW parts, but a lot of people with VWs/Audis try to get rid of that ignitor... not add one to the system!
Im sure that heatsink will help it last longer, certainly never seen anything like that on our cars. OEM its mounted on a flat piece of aluminum and then on the top of the airbox. (with the aluminum exposed to the inside so the air cool it down.)

[marktc]

Re: 2002 Lotus Esprit V8 TT build

I understand why you would want to get rid of it. However, there is no room for coil on plug designs or bigger coil packs.. my options are limited to an ignitor only.. believe me.. if there was a better way.. I would do it.

[marktc]

Re: 2002 Lotus Esprit V8 TT build

IT LIVES!!!!!! However, I do need to make a new video of it.. The current video has the license plate in it.. pooh!