Problem after fitting new endura engine

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Tue 24 Apr 2007 08:25
Problem after fitting new endura engine - Robwilson69
Ok new here in need of help,

ok here goes. i recently bought a fiesta endura 1300 r reg efi with faulty engine, bottom end was knackered i just bought a ka engine the same with only 25,000 miles was mint changed old inlet manifold etc and wiring from old engine fitted all to the new ka engine the drop it in,

now the prob, its start first time but keeps reving real high, i have cleaned the idle valve throttle housing etc but still no joy, i notice that if i disconect the pipe that runs to the air filter at the throttle body end it rev's right but try to stall, so it seems to rev high once the air filter is conneted i have been through all the wiring etc and can't find a logical reason for the engine to just rev up on its own..

any ideas or where to start??


many thanks..
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Tue 24 Apr 2007 09:34
Problem after fitting new endura engine - injection doc
You may have an air leak in the manifold. First check the oil cap! remove it & disconnect the breather pipes and check for the size of the breather hole in the cap, one type has a pin hole ( recommended type & modified) the early one has a bigger hole! make sure you fit the cap with the small breather hole. 2nd remove mouve
fuse 3amp for ECM and leave for 10mins Refit fuse & start but do not touch throttle for 5mins then take for quick drive. If you don't have any air-leaks or wiring issuses this should fix problem
Regards
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Tue 24 Apr 2007 12:45
Problem after fitting new endura engine - Robwilson69
ok i will try these when i get home from work not sure if i mentioned but i used the old oil cap/filter from the old engine as new one looked slightly different, also car seems to try and idle ok but lumpy when air pipe is disconetd from throttle housing, soon as its conected to the air box it revs upto about 4,000 rpm, would it be air box end or inlet manifold prob can't seen any leaks that i can see... i do need to spend more time tonight just tryiong to give you more of a better picture of the problem,

many thanks.
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Tue 24 Apr 2007 14:03
Problem after fitting new endura engine - bell boy
systematically
hydromatically
go through everything that connects to the engine

but not in greased lightning time
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Tue 24 Apr 2007 17:03
Problem after fitting new endura engine - SjB {P}
systematically
hydromatically
go through everything that connects to the engine
but not in greased lightning time


Agreed!

I recently connected a GPS charger (yes, with in line fuse to pre-empt comments!) to my motorbike. Given the low current draw, I didn't bother with a relay and took the feed directly from the tail lamp supply (to ensure the charger is only live when the headlamp is on, which it always is when I'm riding) and grounded to a suitable bolt.

Unfortunately, it was live permanently.

I pulled my hair out trying to find out what was wrong.
After all, the circuit couldn't be simpler.

It turned out the all-black cable supplied with the charger (and from which I cut the ciggy plug as it was intended for car use) was exactly the same (both the gauge and the brand) as the cable I used for my feed and ground wires. The latter had originally been supplied with the Optimate battery charger I use, but unfortunately each manufacturer had used each of the two wires in the cable for opposite purposes; on one, the "written wire" was +12v and on the other it was ground. Conversely for the "blank/unwritten" wire.

Add in a headlamp switch that goes to ground, not open circuit, when switched off, and bingo, you have a charger that is live when you want it dead!

it only took me an hour to figure out!
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Wed 25 Apr 2007 00:36
Problem after fitting new endura engine - Pugugly {P}
What Sat nav are you using SjB ?
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Tue 24 Apr 2007 21:01
Problem after fitting new endura engine - injection doc
If you dissconect the air pipe to the air mass meter & the revs drop it would suggest an air leak & the richer mixture with the air mass connected is making it rev! I would check for air leaks as it only needs a small one!. Has the breather pipe to the oil cap got a split in it? Otherwise check all the plug in connectors & make sure you haven't bent a pin over as you connected back up!
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Tue 24 Apr 2007 23:56
Problem after fitting new endura engine - Robwilson69
ok thanks will check in the morning and post back findings,

many thanks for your help so far.
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Wed 25 Apr 2007 10:23
Problem after fitting new endura engine - Robwilson69
Morning all.. ok i been out to the car this morning tried everything you have all mentioned but still no joy, ok with the map sensor disconected it does rev high but drops goes to stall then does stall but it does try to rev yup still with map doisconnected. i been through all plugs and checked all air hoses for leaks but still no leaks anywhere, i looked at this 3 amp fuse under the bonnet but it is for abs, could this be a faulty inlet manifold is this possible??

also i did not mention i have not fitted the drive belt yet, but sure that wouldn't efffect the rev's...

Headache,, help/......
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Wed 25 Apr 2007 10:39
Problem after fitting new endura engine - Number_Cruncher
If it's revving to 4000 rpm or so, then overrun fuel cut off would normally cut in before this, and the revs would be yo-yoing rather than just being constantly too high. This suggests that the engine management system isn't receiving any indication that the car is at idle throttle position.

How is the throttle position sensed on this engine - is it via a switch or potentiometer. Is this the same part, or was it swapped during the engine change? Is the throttle position sensor set up properly, connected properly, and working properly?

Number_Cruncher
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Wed 25 Apr 2007 11:22
Problem after fitting new endura engine - Robwilson69
hi the yes it a electronic pot and i have changed both these and throtle body to old one that was used befoe, reason why i had to change the inlet manifold was the brass water tap had thread the plastic of the inlet and couldn't be fixed so i was givin another inlet manifold, like i say i have changed so far from old manifold to new the throttle housing plus sensor and idle valve there not much else to it apart from injectors..
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