[Fatzook]

Well I will be pulling the POS out on the weekend and fitting a standard one, so no doubt the issues with the HD clutch will reveal themselves then.

2 other people I spoke to this week have also removed their HD exedy's due to cable snappage.

Perhaps its an inconsistant product??

[CairnsZook]

My VL mounts arrived today, so now the engine is in




The swift thermostat housing clear's the firewall - just.
I have however, spun the lower thermostat housing around, as I was worried the temp sensor plug would get melted. This means I'll have to extend the wires to the plug and run a longer heater hose.




Here's the radiator hoses - a mongrel mix of Baleno, Camry and Falcon...

[birko]

Air con? I used the 1.3 water pipe from behind the water pump.

[xedent]

Nice work buddy.

[CairnsZook]

birko wrote:

Air con? I used the 1.3 water pipe from behind the water pump.

Yeah, the Sierra aircon mounts bolt straight onto the Baleno engine. I'm not sure how to change the aircon pulley to a ribbed one though
I'll get that sorted at a later date, maybe.
It's not like you need aircon in Tassie...

I used the Baleno water pipe from the pump to the back of the engine. I cut it just after the heater hose outlet, then ran it forwards to the original bottom radiator inlet.

[xedent]

Do you have your wiring sorted yet ? Lol

[BlueSuzy]

I used the sierra bottom water pipe out of the pump. Much neater, and runs the stock sierra hose.

I also used the sierra dipstick, as its the right one for the sump. But i didnt measure the Bal one.

What happened with the hole in the intake manifold? Is it a hole or a cast blank like my 2?

[xedent]

I have The same hole it's just below the blank plate ?

[BlueSuzy]

yeah thats it. Its blanked off too up in the manifold?

[CairnsZook]

Hey Tim, I think I may have stuffed up the heater hose arrangement?
Where does the one that comes from just below the thermostat run to?

[jonno_racing]

CairnsZook wrote:

Nice! mine is about the same!! make sure you put a new SUZUKI thermiastat in it before u start. not saying there is going to be a issue with the one you have.. but if you do its a killer to change in the car!~

[zookernator]

Woo hoo!! Top work mate

[BlueSuzy]

CairnsZook wrote:

Hey Tim, I think I may have stuffed up the heater hose arrangement?
Where does the one that comes from just below the thermostat run to?

Back of pump to Heater tap, tap to Left hand side heater box. Rhs heater box to thermostat housing.

[CairnsZook]

Wiring is complete, well almost...

I made a VSS, instructions can be found here - http://www.auszookers.com/index.php?nam ... ic&t=10121
Thanks Dan and Damo

The ECU will live on a bracket I made up behind the instrument cluster.



And here's the Baleno tacho, grafted in to the Sierra cluster.
It was fairly easy to do. There's three screws that hold the tacho in the Baleno cluster.
One is for the tacho signal, one is for ignition, and the other is an earth. Just work out which is which and wire it up!



How do I hook up the engine temp and oil pressure sensors?
I remember reading somewhere if you just connect the Sierra ones they are inaccurate

[steak_knife]

Put your sierra temp sender in the 1.6 & the oil light is just a switch, so the 1.6 one is fine, just connect the std wire up to it.....

& enjoy!!!!!
I just did the 1.6 to Sully, it's the eng Suzuki should of fitted at the factory, frigging awesome!!!

[xedent]

Nice work mate! Bet you cant wait to start it !

Where are you mounting the baleno fuse box ?
Maybe you should also change the speedo over to the baleno one so there both white

[CairnsZook]

I don't have my Sierra temp sender anymore. I sold it for a 6-pack with the old engine attached to it... Where does it screw in Stekky? Somewhere on the inlet manifold? I'll get a new one on Monday.

I've put the Baleno fuse/relay box under the dash, next to the steering column. The high amp fuse box is under the bonnet, in between the air-box and battery.

I've tried to start her. No go
I can hear the fuel pump prime and there is heaps of power to crank her over from my brand new battery. There is only about two or three litres of fuel in the tank. That should be enough though, shouldn't it?

[steak_knife]

http://www.suzistore.com.au/shopexd.asp?id=685

Should look like that & should be under the thermostat..

just looked through your pic's & couldn't see it..

[xedent]

You can do it !!!

Check all your earths !

[xedent]

You might have to try and graft the baleno temp sensor into the sierra cluster ?

[CairnsZook]

Earths are all good.

The spark is very weak though.

Should I be checking the crank angle sensor or coils?
Does anyone know the resistance range of the coils?

[steak_knife]

CairnsZook wrote:

Earths are all good.

The spark is very weak though.

Should I be checking the crank angle sensor or coils?
Does anyone know the resistance range of the coils?

crank angle sen control's the firing of the coil, not the strength of the spark, do you have another coil sitting round??
Make sure the coil bracket has good earth to..

[BlueSuzy]

steak_knife wrote:

CairnsZook wrote:

Earths are all good.

The spark is very weak though.

Should I be checking the crank angle sensor or coils?
Does anyone know the resistance range of the coils?

crank angle sen control's the firing of the coil, not the strength of the spark, do you have another coil sitting round??
Make sure the coil bracket has good earth to..

Coil bracket? Its twin coil, on the head..

I run the stock sierra temp guage. Or try to run the baleno one. Or run aftermarket. You get to know whats normal for your motor. Mine sits at 1/4.

The oil pressure, i run just the stock wire. And i have seen the oil light come on from low pressure from low oil

[CairnsZook]

No, don't have any spare coils to try. There seems to be a better spark coming out of the rear coil.

The dash lights don't seem quite right either. When I turn the key to "ON" all I get is the check engine light. Shouldn't I get more?

[xedent]

Yep I thought all should display ?

[CairnsZook]

So I pulled the lume out today and checked all the wiring - again.
A couple of things were not earthed, so I connected them up. Still no luck.

I've tried pulling the starter wire of the solenoid and the fuel pump works as it should. So I still think I may be missing an earth somewhere.
Does it really matter exactly where things are earthed? Battery/body/chassis/block???

[JrZook]

CairnsZook wrote:

No, don't have any spare coils to try. There seems to be a better spark coming out of the rear coil.

The dash lights don't seem quite right either. When I turn the key to "ON" all I get is the check engine light. Shouldn't I get more?

This is concerning. Got that all sorted yet?

[CairnsZook]

Not yet Dan.

I've just found some more Baleno wiring diagrams, so I'll start from scratch

[CairnsZook]

After spending another couple of days on this bloody wiring she still won't fire
When I turn her over, she cranks and I sometimes get a bit of a pop and a little exhaust gas from the manifold (no exhaust fitted yet).

She's got spark and the fuel is getting to the injectors, but maybe not to the plugs???

I've checked all the connectors to the ECU, and also checked the continuity of ALL the wires from the ECU to each plug, all power sources and earths.

The dash lights are still not right also.
I've got a Falcon alternator connected to the Sierra W/Y wire which runs into the Sierra lume and back to the battery (fusible link is missing for some reason).
The W/R and B/W wires are also connected.

The original Sierra wiring at the battery is a little suss too. As stated, the fusible link is missing, so it's wired direct for the time being. I also have another red wire from the positive terminal running back into the lume via a fusible link. This does not appear on the wiring diagram... It runs to a large round connector on the passenger side firewall, then through into the cabin. Wires on the plug are R, LG, LG/R, BL/R.

I'm thinking about tearing into the original Sierra lume now. Although the car did run previously, so I shouldn't have to...
Maybe I'll just have to get the bloody thing towed to an auto sparky

[JrZook]

CairnsZook wrote:

After spending another couple of days on this bloody wiring she still won't fire
When I turn her over, she cranks and I sometimes get a bit of a pop and a little exhaust gas from the manifold (no exhaust fitted yet).

She's got spark and the fuel is getting to the injectors, but maybe not to the plugs???

I've checked all the connectors to the ECU, and also checked the continuity of ALL the wires from the ECU to each plug, all power sources and earths.

The dash lights are still not right also.
I've got a Falcon alternator connected to the Sierra W/Y wire which runs into the Sierra lume and back to the battery (fusible link is missing for some reason).
The W/R and B/W wires are also connected.

The original Sierra wiring at the battery is a little suss too. As stated, the fusible link is missing, so it's wired direct for the time being. I also have another red wire from the positive terminal running back into the lume via a fusible link. This does not appear on the wiring diagram... It runs to a large round connector on the passenger side firewall, then through into the cabin. Wires on the plug are R, LG, LG/R, BL/R.

I'm thinking about tearing into the original Sierra lume now. Although the car did run previously, so I shouldn't have to...
Maybe I'll just have to get the bloody thing towed to an auto sparky

If all the ECU wiring is correct and you have checked all the connections at the ECU than that area should be ok. You have spark, the fuel pump primes and runs so that indicates the comp is firing up. Get a node light and check if the injectors are pulsing or try spraying some starting fluid down the intake and see if you can get it at least to fire. You running low on options to what is wrong now, you've eliminated nearly everything. Only two things i can think of now is fuel and timing. If you spray starting fluid into the intake and she fires then it seems you have an injector/fueling problem. If it still doesn't fire with the fluid but you have spark the timing could be out. This thing runs a crank angle sensor yea? any chance the connector could be on backwards? This can put the timing out.

Dan