My suzuki lives

[Rotazuk]

The short version .

My zuk ran again today for the first time in about 9 months . Idling like crap but was idling .

The long version . You have been warned .

A couple of years ago I spent nearly a year moding my 413 , it got toy axles , a nissan ca18de engine and gearbox etc , then a few months after that I rolled it off a hill . Not a good start to life .
Anyway it got a new front , fibreglass LJ80 one . During this time it went well , I dropped a coil or two and every month or so the idle would creep up so I would wind it down on teh throttle stop and all was well .
After a while it started backfiring and running like crap below 2000 rpm , above this normal . After checking and replacing everything that controled ign and fuel , including the ecu , I was getting a little frustrated . I decided to do the Thames larrie sanson last january with it running like crap , it was rather hard to drive and half way through the day it dropped another coil . So in a crappy mod I dumped it on the trailer took it home and put the wire cutters through the ecu wiring . I felt much better

So I pulled the megasquirt I had in my range rover out , this is a kitset efi computer . Spent about two months and a couple of hundred dollars getting the factory cam sensor to work , in the end it cost about $5 , a couple of resistors . But it was running again without the factory coil packs . Unfortunatley it still had the high idle problem .
So it got pushed out of the shed for other projects , a few months later I decided it has to be fixed so looked for a new intake manifold . Found an entire engine for $100 , and took the manifold off . Took the one off the zuk and found foam stuck in number 3 intake passage . Swapped intakes and tried again , alas the dam thing would not start . So out of the shed it went . A few months rest must have given it time to heal as it went back in teh shed yesterday and I had a play tonight and the dam thig fired straight up , I had not done anything . It ran like crap for a bit but an increase in idle fuel improved it .

It is not running well but it does idle at around 900 rpm much better than 2000 rpm . So once I learn ow to tune the fuel and ignition without blowing it up it should be back out in the bush again .

So it was either the foam in teh intake or a hole in teh intake manifold somewhere , either way its on its way back to good health and I am stoked .

Now if I got out to the shed tomorrow night and it does not start there will be a small fire in sth auckland

Cheers

Chris

[mercutio]

will it be ready for the BBQ then

[meatc]

Congrates on getting it runnin again :thumright: :thumleft:

Was hoping you were going to pin point the problem so when i have it you could tell me how to fix it but never mind.

Hope it starts tomorrow but can under stand the frustration. I have been known to throw the toys and cut stuff in a fit of rage. It always makes you feel better (until you have to fix it.)

Now get it out of the shed and into the mud.

[Dr_PC]

Laurie Sanson not far away

[Rotazuk]

Well due to the up coming larrie sansons etc I have decided it would be quicker to put the factory ecu back into the zuk now that the idle issue has been solved . The megasquirt ecu needs a bit of time spent to tune it etc , time I do not have .

So I have started piecing the wiring back together , remeber I said I took to it with cutters in a bad mood , well thats come back to haunt me



The rest of the loom is used by the megasquirt



So with about 60 wires to piece together tomorrow is going to be a long day .



So wish me luck . Also I will have to carry spare coils , luckily they are quick to change .

Chris

[coxsy]

geess good luck with that mess mate

[meatc]

When ya finished can isend ya mine.

The guy i bought the engine off was too lazy to pull it out and cut it

Have fun keep the bevves comin i say.

[Dr_PC]

Someone else that I need to take the sidecutters off me thinks

[Sadam_Husain]

You'll sort it Chris

[Rotazuk]

Well since I was , er cough cough , sick today I spent the day piecing together the loom , what a mess . It was in more pieces than I thought . Had the required spare parts once the job was complete so I figured it would be a winner .
It started ok but only ran on 2 , sometimes 3 cylinders , on the bright side it was not backfiring like it used to . After changing the front coil and stuffing around it seemed to clear itself and now seems to run fine . Once I get a few things sorted I will take it for a spin down teh road and make sure its good .

So now all I need is a new rear diff , its a toyota but will post a want message , straigthen the front tie rod , replace the pitman arm ball joint and prperly mount the powersteering resivour it will be good to go , I hope .

[Rotazuk]

Well since it looks like the zuk will be in action for the summer it needs a few things fixed up on it . Some things it never got done on the rebuild and some things are bit that have broken .

First up is the steering , I have started with that to stop me driving it down the road , cause if I do that it will be deemed go to go and all this other stuff will not get done . The pitman arm ball joint is stuffed largly due to it being tweeked to far in axle drop . So thats out getting rebuilt and I will talk to the guy that made my drag link and see what we can do .

The tie rod is also bent . So after a little deliberation , How beefy should I go . As they say its easier to straighten a bent rod in the bust than try and join one back together and you don't want the ball joint to be the weak link .

So this is what I did .


Cut off the bent bit , found a bit of pipe same wall thinckness as original but bigger Dia .



Slid the ends inside the tube and welded it back together .



A quick coat of paint and its back in .



This weekends project is to build a new trailer , I sold the range rover I had for towing while the zuk has been sitting , so everything has to go on a diet so the wagon I have now can tow it . That will keep me busy all weekend then some .

Will post up some other pics as I do other bits , if time allows I will do the rear disc conversion I have had for teh last year also .

Cheers
Chris

[wopass]

so are we gonna see you on the 1st December at the BBQ ? ? hope so,need someone to test the swamp first