intermittent start after engine swap - No spark. - LotusTalk - The Lotus Cars Community
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post #1 of 9 (permalink) Old 08-01-2017, 01:46 PM Thread Starter
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intermittent start after engine swap - No spark.

OK so I installed a replacement engine in my Exige S after I grenaded mine. I went to start it today and it had no spark. I managed to get it to start a few times, but it wasn't reliable and I can't get it to start again now. Here is what I have tried.

1. Changed Cam Position sensor to the known good one from my old engine. Worked on first startup, came up to temp, turned it off and it wouldn't start again.
2. Removed and replaced cam position sensor, started again, ran for about a minute then died.
3. Tried #2 again with no luck.
4. re-verified that I had fuel and no spark
5. Changed Crank position sensor to old known good one.

Now when cranking it mostly just cranks and cranks, but occasionally when you try to start it it will sound like it is going to start for about 1 revolution then stop. You have to release the button and press it again to get it going. There are also loud bangs from the exhaust from time to time that I assume are unburnt fuel.

I have a code reader and most of the time there has been no codes. The only 2 that there have been are

After the first time I tried to crank it to get oil circulating it had a Rocker position error P2646 which never came back again, then after it died I had the throttle position errors. P0638 and 2108 which I have seen before on the car a few times and never meant anything. I cleared them and they never came back.

Not sure where to go from here, if I knew which pin on the ECU connector it was I would do a continuity check on the cam position sensor wire which is the most likely culprit? I know it is RC1 and RE2 from the wiring diagram, I don't understand how that relates to reality since there are no marks like that on the connectors.

Thanks for any help!

2007 Exige S with almost every track mod...
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post #2 of 9 (permalink) Old 08-01-2017, 03:42 PM
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Apparently one can command the ECU to fire the spark plugs: https://github.com/t4eeditor/Binary-...ki/OBD-Mode-2F

It looks like mode 0x2F PIDs 0x161 thru 0x164 (in pairs of spark plugs- the ECU may be compatible with engines with more cylinders).

I have never tried this, but it may be helpful as a troubleshooting method.
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post #3 of 9 (permalink) Old 08-01-2017, 04:58 PM
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Gosh...

That sounds exactly like my symptoms. I had a "Cam position Sensor High" code reading.

I had a clean break on my intake cam. I took the valve cover off and that code was not a fluke. Only cylinder one was firing giving it a pop of unburned fuel every time it hit.

Take a look at your timing chain tensioner and try to gestimate how extended it might be. Mine extended fully and wore my cam journal entirely down and then I had a "lucky" break just off idle.

I could not figure out what was wrong until I inspected my cam's very closely.then I saw the ugly truth. I hope and don't expect your issue is same as mine, but your symptoms sure sound similar.

The only other random thought is did you "lock" the VVT ( timing/ phase) that is on the end of the intake Cam? That could just be a silly thing to suggest...???

Actually, I guess my entire post might not be that helpful given you have taken the Cam's off and inspected. right?

L O T U S

Last edited by Motard; 08-01-2017 at 05:06 PM.
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post #4 of 9 (permalink) Old 08-01-2017, 05:44 PM Thread Starter
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I have not removed the cams, I did remove the valve cover and all seemed well. Note that the engine did start and run for 5+ minutes once, it seems unlikely that the cams are broken in any way if that is the case, but I should have a look.

2007 Exige S with almost every track mod...
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post #5 of 9 (permalink) Old 08-02-2017, 03:14 AM
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Sure sounds like an electrical connection

If you look at the color codes I think you may be able to find the logic behind the connector pinouts
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post #6 of 9 (permalink) Old 08-02-2017, 08:26 AM
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- Is the reluctor ring on the crank shaft installed with the "F" facing out?
- Is the ground on the VVL housing tight and clean (ground for spark)
- all fuses visually inspected

I had an 05 not long ago with very similar issues, even after doing pinout test, inconclusive. Replaced engine harness, and fired right up. 06 and up harnesses are actually pretty cheap, 05 not so much.

In 2006 we had an issue in the harnesses with the pin spreading open. We would take a factory ECU pin and run it through the connectors, any that didnt have drag we would re pin the female side on the harness. I have the pins if it is something you want to check.

Best of luck!

T.J.

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post #7 of 9 (permalink) Old 08-02-2017, 10:04 AM Thread Starter
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Quote:
Originally Posted by GatorMS_Service View Post
- Is the reluctor ring on the crank shaft installed with the "F" facing out?
- Is the ground on the VVL housing tight and clean (ground for spark)
- all fuses visually inspected

I had an 05 not long ago with very similar issues, even after doing pinout test, inconclusive. Replaced engine harness, and fired right up. 06 and up harnesses are actually pretty cheap, 05 not so much.

In 2006 we had an issue in the harnesses with the pin spreading open. We would take a factory ECU pin and run it through the connectors, any that didnt have drag we would re pin the female side on the harness. I have the pins if it is something you want to check.

Best of luck!

T.J.
T.J. I appreciate this because you gave the right answer, but I had finally figured it out before I read it. Maybe I should just call you first next time!

The problem was the ground on the VVT. It was installed, but the screw that I used was like 1mm too long, and though it looked tight, it wasnt tight on the ring. Changed out this screw (after I did continuity tests on the Cam sensor AND the crank sensor, which involved learning to dissassemble the plugs etc.).

Fired right up after I tightened the ground!
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2007 Exige S with almost every track mod...
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post #8 of 9 (permalink) Old 08-03-2017, 08:13 AM
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Glad you got her figured out!! Now go put some miles on it!!

T.J.
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post #9 of 9 (permalink) Old 08-03-2017, 09:31 AM
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Nice work, good information considering I am going to be near this process hopefully in about 2 months or less.
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