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Thu Apr 19, 2012 9:18 pm

Help me out here guys and girls, this new engine is beating me down...

I have a new-built 2160 fuel injected 'turnkey' motor from Pat Downs/CB Performance for my 58 bus. It replaces a 1916 dual carb motor.

Over the past few weeks/months I have been fitting various bits and pieces which I'll list shortly, but to get to the core of this post quickly, I did the final hookups this morning, went to turn it over and it simply doesn't fire. Sounds like the battery is flattening during cranking, but give it five minutes and it's still got good charge and ready to crank again.

Tried my neighbour's battery from his diesel which has, like, 950 cranking amps, exactly the same result.

The other thing to note is the starter is getting very warm, like too hot to hold onto. It's a new Compufire high torque starter.

The motor was bench run before it was shipped, or so I am told.

Any ideas?

Here's the work that has been done over the last little while, just to rule out (or open up) possibilities:

Battery is relatively new, and has been on the charger for the last couple of days just to make sure it was ready to fire up. Reading 12.6 volts
New gearbox, nosecone, mounts, couplers. I have relocated the tranny ground strap and it now runs from one of the tranny casing nuts to the frame (I did this because I couldn't recall exactly where it was supposed to go.). The tranny strap itself is new and shiny. Ground points have been cleared of nay paint.
New high torque starter coupled with solenoid
New engine has all new parts including alternator and coil pack (not coil/distributor)
Just put 10 litres of premium fuel in in this morning.
New electric fuel pump that seems to be making all the right sounds.

There are other bits and pieces but I am only listing things here that might affect the current problem with the starting of the motor.

Obviously there is a whole new loom for the fuel injection system to go with the new motor that is all hooked up and nothings seems amiss.

All the old wiring (like to the starter) I have been very meticulous about replacing the way I found it before I pulled the old motor. I could, of course, have gotten something muddled, I suppose, but I was taking notes and being pretty careful.

Any things to try?

Thu Apr 19, 2012 11:40 pm

Well time to figure out what the engine isnt getting. To fire it needs fuel/air/compression/spark........and all in the right order. Spark should be easy to figure out........start testin plug wires for spark. Fuel? dump some down the air intake..... Valves adjusted correctly?
How long are you cranking the starter? If your crankin it for too long then sure it will get f in hot. Its also a NEW motor....they will be tight. You did put oil in it right...........just checkin.

Thu Apr 19, 2012 11:57 pm

Have you turned the motor over with a wrench to check for tightness? If the motor is really tightening up.....then youd better hope it not fire, or your engine will be shitting bearings.

Fri Apr 20, 2012 12:16 am

Double check the ignition timing and the order of the spark plug wires. The starter should not be getting that hot. As was noted, see how hard the engine is to turn over by hand.

Fri Apr 20, 2012 12:20 am

quartermilecamel wrote: Well time to figure out what the engine isnt getting. To fire it needs fuel/air/compression/spark........and all in the right order. Spark should be easy to figure out........start testin plug wires for spark. Fuel? dump some down the air intake..... Valves adjusted correctly?
How long are you cranking the starter? If your crankin it for too long then sure it will get f in hot. Its also a NEW motor....they will be tight. You did put oil in it right...........just checkin.

Spark is good, valves are adjusted ... Oh, oil!

Nah, just joking, yep, oil is good. Can turn it with a wrench .... tight, but not too tight.

Fri Apr 20, 2012 12:45 am

Update: Pulled the starter and, running it on the bench i.e. not under load, it runs too hot to handle after about, say, 20 seconds of continuous running.

Fri Apr 20, 2012 4:16 am

Its normal for it to get hot after 20 seconds. Thats a good bit of time for that motor (starter) to spin like hell. Did you check spark, fuel and all the simple things and make sure all electrical connections are good? Again the starter will get hot after 20 seconds. Count to 20 and then think do you turn your car over that long to start on usual.

Fri Apr 20, 2012 5:12 am

Update: Swapped in a 40-year old starter from a beetle sitting in my neighbour's paddock, probably hasn't been started for 20 years, kicked the engine over first time.

Today's lesson: shiny, expensive bling is exactly that: shiny, expensive and not much else. Avoid Compufire starters if you're in the market. They're shit.

Fri Apr 20, 2012 6:26 am

57Airhead wrote: Update: Swapped in a 40-year old starter from a beetle sitting in my neighbour's paddock, probably hasn't been started for 20 years, kicked the engine over first time.

Today's lesson: shiny, expensive bling is exactly that: shiny, expensive and not much else. Avoid Compufire starters if you're in the market. They're shit.

X2! Had a very similar experience with my last test stand engine. Turned out to be a tired test stand starter too! Glad you have it figured out! 8)