We all know they exsist. We all know that they are inevitable. Then WHY are new car bugs such a pain, and still come so unexpected?
Maybe I should have expected them, or maybe I should have known better, but somehow, just as I think I’m done and ready to go, something sets me back. This weekend was no exception. After the disappointment of missing the Orlando race due to a starter mis-alignment problem, I was happy that the fix wasn’t nearly as expensive nor as complicated as I originally feared. Fixed and ready to go by Thursday of this past week, I was very excited to have Dennis Lugo (Excessive Engineering) coming up on Saturday to help me get the car dialed in and tuned. As he was traveling up to Phenix City from Orlando, I decided to meet him at the track to have the car unloaded out of the school bus (yes, the SCHOOL BUS. Don’t ask, the trailer was INOP) and situated before he arrived around 3pm. Now, earlier during the week the car would start when cold, but would not re-start after some heat was in the motor, or would crank but not stay running when warm. Figuring that it was in the start-up programming, I assumed that it was one of the issues that could be resolved once Dennis arrived. So, I started the car up at Phenix City and drove (as in cruised) the car down the track to get used to the Bruno. After stopping briefly at the top end, the car would not go back into high gear on the return road trip. Back in the pits, Dan looked at me skeptical as to why, thinking I had forgotten to eat my Wheaties again. Wrong, one snatch against the shifter, and it snapped the base of the shifter in two places. Something was wrong with high gear. Dan went back to the shop to weld together the shifter mounting assembly, adding a strengthening plate to the back and we re-installed the shifter. By this point, Dennis is almost to Phenix City, so I finished bolting up the wheelie bars until he arrived.
As soon as Dennis gets there, we plug up the computer and get to work. Cranked it up (with some fuel injected into the throttle body elbow, blower-style) warms up, and Dennis begins his magic. For those that are not aware, Dennis can tune nearly every system out there, he has been tuning since the early days of DFI, and has already been using the Big Stuff 3 system (the system on the T-Bird) since last year. After a few minutes, we shut down the car to make some changes in the program. When to crank it up again, and… NOTHING. Squirted fuel in the motor, it started for a few seconds and then cut off. “Yep, that is what it was doing. And then we can’t make it start again.” I told him. So, we started troubleshooting. Ignition firing? Check. Enough fuel at start up? Double Check. Timing right? Check. Firing order correct? Check. All cylinders firing? Check. We pulled the plugs and replaced the blackened plugs with fresh ones. Still nothing. Dennis changed the map. Nothing. Start up maps. Nothing. Every imaginable component. Nope, nada, nothing. I have never in my years of knowing Dennis, seen him stumped like this…. and I’m worried.
By now, its getting dark, and the test session is over. So, we loaded the bird back into the bus, and headed to the shop. After a bite to eat, Dennis, Josh and I continued to try and diagnose the problem. Dennis continued with the map. Finally we pull the plugs again. #1 is soaked with fuel, while the rest are dry. Dennis determines that the #1 fuel injector must be stuck. By this time, its 12 am. So we wake up Walt to get the number to the owner of the only set of 160# injectors we know of in town. Thankfully, Kelvin makes a call, and we are on our way to Smith Station, AL to a set of brand new injectors.
Back at the shop, Dennis replaces the injector in question, and I hit the starter button again. Vrooom! Started up clean, but all of a sudden I look up to see the intake valley ON FIRE. We rush around trying to throw water on it before resorting to the powder fire extinguisher to put it out. One puff, and the fire is out, but now we have a wonderful powdery mess to clean up. Apparently, when we left to get the injector, I forgot to plug back in the #3 spark plug wire. It arc’d and ignited the fuel in the intake valley. Big whoops on my part. luckily nothing was damaged in the fire. So, at 1 am, we open the bay doors, push the car out, and wash all of the powder out of the engine compartment. After drying everything out, and making sure everything was plugged up correctly, we tried again. It fired, ran for a few minutes, and then quit again. Hmmmm. Checked the plug, and it was not soaked as it was last time. We figured now that the injectors were running correctly, we’d have to rework the map to keep it running smoothly, since we had been trying to compensate in the map for the bad injector. Seeing how it was almost 2 am, we called it a night.
This morning, we started off bright and early again. Got to the shop around 8am, and got back to work. We were ready to set the timing, and adjusted the crank trigger again (after some adjustments last night). But the car started acting up. Now, it wouldn’t crank at all. A few more hours of trying, and finally Dennis started unplugging injectors. Sure enough, with 2 injectors unplugged, the car started right up. He switched injectors, and unplugged another 2. Fired again. So it wasn’t related to a single bad injector, it was something within the computer. Dennis determined that there was an injector driver problem within the box, and with that our day was done.
So, the computer has been sent back and the injectors sent off to be cleaned. It’ll be next week or so before we try again. At least we figured out one of the problems. GOTTA LOVE NEW CAR BUGS!
