Introducing FAQ Memberships 04/17/2017I would like to introduce everyone to the FAQ memberships. A fun way to fund the site and to contribute for those who are interested. Everyone starts as a Solex Member. This membership is free and not much visible is changing (I limited the personal message storage to 150). Kugelfischer membership. As a reward for your donation of $20.02 per year, you will not see any external advertisements, the site will look cleaner and run a bit faster. You will also get a couple of BMW 2002 FAQ Stickers. Turbo Membership. As a reward for your donation of $50.02, you will not see any external advertisements, the site will look cleaner and run a bit faster. You will also get unlimited Personal Message storage, ability to create Private and Restricted Photo Albums. You will also get a couple of BMW 2002 FAQ Stickers and a Bottle Opener. Alpina Membership. As a reward for your donation of $100.02 per year, you will not see any external advertisements, the site will look cleaner and run a bit faster. You will also get unlimited Personal Message storage, ability to create Private and Restricted Photo Albums, and an ability to upload Movies to the gallery. You will also get a couple of BMW 2002 FAQ Stickers, a Bottle Opener, and discounts on our accessories at the store. There is also a fancy title that comes with each membership.
So, I've been busy selling off some of my cars, and haven't really been giving this project as much time as I'd like. But, I managed to finish the wiring harness and start the engine this week. I've updated the wiring diagram in the first post to reflect the current configuration. After the successful start, I'm taking some time to reconfigure my engine stand set-up so that it will be less ad hoc during the tuning phase.
Here is an overview shot of the engine as it sits this evening:
I ended up going with pencil coils on plug from a 2003-04 Honda CBR600RR motorcycle. I used a Bosch 0 227 100 211 igniter from a late '90s / early 2000s Volkwagon to fire the coils based on logic-level waste-spark signals from the MicroSquirt board. They are so low-profile:
For injectors, I used 19#/hr units that are much cheaper when you buy the rebuilt "Ford" versions on eBay (p/n 0280150943). I discovered that you can't re-pin the OEM AMP connectors in the BMW harness, so I bought new AMP Junior Timer Power connectors and terminals from Mouser for both the injectors and the ECU temperature sender:
Here is the PWM-driven idle air control valve, from a Geo Metro / Suzuki Swift 1.0L engine, mounted to a boss under the intake manifold. I am honestly not sure if it's working. The open-pipe first run was very loud and necessarily brief as I have no radiator installed. it remains to be seen whether this can move enough air to control the idle:
Here you can see the throttle body, TPS with adapter from 02again, and GM air temperature sensor (next to the dip stick):
I had the wiring tidy for the start, but then jumbled it in moving the engine around the shop this morning. I need to create a little panel/console to mount everything to so that everything remains orderly:
That's the news for now. The first start was so easily achieved, but the real work is really in this next phase of tuning. Especially given that while I am experienced with building wiring harnesses, I know next to nothing about tuning MegaSquirt.
I've been travelling and tied up with other projects and have not had a chance to start working on the 2002 but I'm almost, almost, almost ready to begin work. Most of the parts I ordered have arrived. I figured an image of all the stuff going into the car is in order, and laying it all out helps me get organized. I also wanted to identify duplicates (there are a few duplicates for various reasons....). So here are some of the parts I'll be working with over the next couple of months.
Arrived so far (in image):
All new cooling system components (water pump, thermostat, silicone hoses, belts) except for the radiator, which I will evaluate when I pull. I do no think I will be putting the fan shroud back on.
A new alternator (and bushings) and voltage regulator
A new header as part of the emissions-control removal (2 headers, actually...)
New cloth braided fuel and vacuum lines
All new brake components including pistons, drums, discs, calipers, pads and flexible lines. I'll examine the hard lines once I start on this.
All new suspension components including bushings, struts, shocks, springs, mounting hardware and sway bars.
New World Upholstery seat covers and new seat back/release/hinge cover hardware.
A shifter rebuild kit
That foam pedal cover so I don't see the road through the pedal box anymore.
New door hardware (gaskets, inside handles, some knobs)
A new passenger side mirror (none on car originally)
A lot of gaskets (Valve cover, timing chain cover, manifold, etc.)
Nuts, bolts, studs, wave washers....
New badges and emblems. (I can't stand seeing a BMW with faded badges or bent emblems. It's like wearing a suit but having dirty shoes.)
A few of the many stickers that I will be replacing when I paint.
One of the two sets of wheels I purchased. (The other set is coming from Austria....no idea when it will get here.)
A custom Noah car cover from the Cover Store. These covers are really terrific and they use the same material that BMW uses on their branded covers. I have 4 or 5 of these.
A few things are on their way:
A new OEM valve cover because I'm pretty sure mine is warped.
Carpet from Esty. No hurry on that as it will be a while before I am ready for it.
I ordered some single-stage acrylic Urethane (I think) paint in Polaris Silver to paint the under-body and engine compartment.
A few things I still need to deal with/purchase:
Rear differential gasket, once I confirm I need one.
All of the aluminum trim on the car, once I pull it all off.
A brake master cylinder rebuilt kit and possibly a brake booster (Something in there is leaking pretty bad)
A steering box rebuild kit, possibly.
Drive train components, once I evaluate them. (Guibo, CV joints, wheel bearings, etc.)
Distributor, condenser, spark plug wires, etc. Considering a 123/Tune+
All of the exterior trim strips.
The To-Do list is forming:
1. The first order of business is relatively simple, but important in the grand scheme of things. I need to fix the fuel line leak/flow issue so that the car starts right up when I turn it over. Knowing it should start right up will help a lot when dealing with other systems (if it doesn't)
2. Then I'll tackle the emissions control items.
3. Replace the water pump, thermostat and related components
4. Replace brake components
5. Evaluate drive train components
Those of you who are Project Management people know that this is a rolling wave process. Detail is high in the immediate tasks, not so high right now in the more distant tasks, with future-task detail increasing as current tasks are completed. Overall, I first want to eliminate and clean up after any and all fluid leaks and get the engine running optimally. Then I need to address the suspension/drive train and determine how/what/when I want to paint the under body and engine compartment. I'm not really set up to pull the engine, drive train and front/rear sub frames but haven't completely eliminated the idea. And there is soda blasting to be done to expose rust and remove a really awful Maaco paint job from 1985.
Today I rented a two car storage space and will be storing my Alfa and one of the other convertibles in that for the winter. This will give me a little more room in this garage to work.
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