Hah! - I'm not worried about it - I've practiced on the OEM heads on the broken 3.5 that's been my test mule for the new manifold. With that Dremel cutter tool, it's actually easy. I marked the upper part of each Cosworth port with a blue permanent marker, then used a thin and sharp scribe to mark the injector locations. I'll wet the small pieces of microfiber towels and stuff them in tightly before cutting out some metal here and there, then vacuum up the chunks. I just prefer to wait for a warmer and sunny day to do this.

 

I like the idea for the nitrous. Should work well, but dont get too close to the end of the plastic(near the gasket) so the im is not too weak in those areas.

 

Hmmm... good point - it might get pretty cold around the tips of the nozzles. Good thing is that there is a honeycomb of reinforcing plastic just behind the new ABS strip, which is now firmly screwed into the honeycomb material. The rear of the UIM has a support point which sits right on top of the #5 coil, which helps bear the weight of the extra TB and extension tube.

I haven't bought any Induction Solutions fogger nozzles yet, because I want to focus on getting the " 07VI " project completed and running first. Besides, twelve $42.50 nozzles are kinda expensive all at once. I have every other thing I need for one stage, so I might do nitrous in two stages - but I still gotta have the fuel cell, pump and regulator for the ethanol tank ready first.

 

Yeah, I prefer your method of expanding the injector ports, since it is mostly about the angle. Had to get my hands on a nice inner caliper to get the ports as close to each other in diameter as possible, my previous 'eyeballing' was off by upwards of 2 mm's at some depths, even though it felt spot on. The engine would probably run without touching the port walls, just wouldn't be optimized - but then again that might add anxiety to the spray.

 

Looks like I'll be using this spark plug: ( heat range 8 )


http://www.cosworthusa.com/store/pc/...&idproduct=389

 

We finally had a sunny and warm day today, so I've been working on the car since 9AM (gotta have coffee) until I started up the car at 8 PM.

I pulled the old manifolds and fuel rails, pulled the plugs just to check (looked good) and began scribing the heads for some porting. After I got them all marked, I stuck wet cloths in the holes and began grinding on things.

Lots of pix to follow. Oh yeah, it started right up, idles great, but I've got a fuel leak, so I may pull the lines tomorrow after work. Then maybe I can go for a drive...

 

Running at this point!



I still need to make a place for the intake temperature sensor, and re-mount the parts on the aluminum plate that the ECU wants to be connected.


So far, so good....

 

Nice progress! That's what I like to see.

Find a way to mount the nozzles yet?

 

Yes I did - you missed it in the earlier threads. See that 1" piece of ABS plastic across the front of the manifold? That's where they will mount.

 

My intake temp sensor is just hanging somewhere near the maf

 

Nice, good idea!

 

She's alive! How does it sound?

 

I did temporary mounts for the odds and ends that the ECU thinks it needs to live, made a 3/4" hole to mount the IM temp sensor, and generally finished up the filter-MAF-TB hookups (no photos). I found my fuel leak and re-tightened the hose clamp, and re-tightened the front valve cover where a drip had appeared. Except for idling a little slower, everything was normal. Cleared the usual codes, then I went for a drive.

The car is now stupid faster through the gears, making power before 4K now and breaking the tires loose from 4K on up through three gears. When it shifts (at 6300), the car goes in several directions and keeps on spinning the tires (225/55/16 BFG GA/Tforce) until I chicken out. City streets are no place to do this.

I haven't even adjusted the idle screw yet. Daymn. All the tricky stuff with the TB and cable mounts all worked the first time. The porting went very well, using a scribe and a Dremel cutter and small sanding drums. I'm prepared to mount and plumb 12 nitrous nozzles for rock-and-roll. OK, I find this hard to believe, but the car really does run stronger after the 07VI updates.

I gotta get onto the EU cable build and see if I can get that to work, while I'm on a roll. Shifting at 7500 or 8000 could be very exciting. So far, so good.

EDIT: After clearing the codes. I went out for two very exciting drives, and when I came back home, there were no codes !!! I'm still amazed...

 

Nice man!!!! Makes me wanna do a newer VQ swap

 

Go for it - I recommend the GTR engine (and the rest of the AWD stuff) for the ultimate WOW factor.

 

Grey- Kinda OT, but how are you planning on raising the rev limit on your 99? As far as I can tell, no one with a 99 has sucessfully raised the rev limiter using a 99 ECU, with emanage.

 

Really, then I'll be the first one! The functions are the same up through 99, but there are four wires that have different connections on the 99s compared to 95-98s. DandyMax was good enough to point out the important one in his EU document. Besides, I'm going to need the EU for the turbo project to follow next season.

 

Am I understanding this correctly, you're spinning 3rd NA with compression in the . . . high 8's?

I can't wait to feel this thing w/ 11.5:1 at 7500K, the earthquake in Japan brought my build to a complete standstill.

 

I followed the wizards thread, and he couldnt raise the rev limit. Even with the magical help of DandyMax.. That's what turned me away from the EU's in the 99's.

Last I checked I believe The Wizard sourced a JWT 99 ECU with a raised rev limit.

 

My actual compression is 10.6:1 , with the 11:1 CP pistons and 2cc bigger-than-stock combustion chambers. Other than that, yes. I still haven't floored it yet, either. The way it accelerates, I wonder if at part throttle the ignition timing is advanced a bunch which makes the car pull harder. I need to install my BlatZ datalogger on another laptop and start gathering some data.

It's sprinkling again tonight, with rain at 70% chance into Saturday. The HPT NHRA nationals have the finals on Sunday, so I'll be there for the biggie and to meet Don Garlits. Saturday I want to go to KCIR , if it doesn't rain, and check out the Vamp racers and see if I can join up and race in their events. It's kinda bracket racing but with lots more street classes and a couple of 1/8 classes as well.

So how did the earthquake affect your build? I can see where lots of factories were knocked out. Talk about bad luck....

 

Well, the Wizard certainly knows what he's doing.. I'll need to backtrack his work and see what happened to him. There's always a way, though, and I may need to change a few wires and drop in my backup '98 ECU if the 99 won't play nice. As you know, the raised rev limit depends on the ignition pulse being present up to 8K, and the injector pulse is also there but with about 1/10 duration. If either is completely missing above 6500, the EU can't do anything about it. So I'll do something else.....

Thanks for the heads-up on the 99 ECU.

 

Send me a log of you redlining it when you get a chance. I will see if I can make a extended rev map for you. I have done it on a couple of 4th gens and 2 5th gens. I can prob do it on a 99... Hopefully

 

Wow grey you're engine's up and running? I've been away for a long time! Good stuff.

Regarding the Wizard's 99, we discussed it at the time and IIRC he indicated his ECU had zero pulsewidth above the limiter. However he never sent me his logs/files to look at so I am unable to personally confirm or deny what the situation is with 99's. And since I haven't been following the scene the last few years much I have no idea if anyone else has done it on a 99.

But as you say Grey, you can move to an earlier ECU if you don't mind losing NATS

 

Nice. Glad its back up and running. I think I may try alittle porting before I drop our motor back in.

 

Thanks for the offer - it may be a while, but I'll "get er dun".

 

Hello! Nice to see you're still around... how's your 3.5 coming along? Yup, I've sure learned a lot about VQ35s lately, and I am greatly relieved that the project actually worked. So you think that Wizard's 99 lost any pulses above the limiter, huh? I think I have a way to quickly check that out - I have a dual-trace oscilloscope in the garage that I can put on both a coil trigger wire and on an injector wire off the ECU, and rev the engine above rev cut and see what I can see. Probably one at a time, but the scope is a good one, so I should be able to see the pulses well, especially after dark.

FWIW, the "07VI" manifold update is really worth the work....

This should let me known what my choices are (and I'll report back here) - and I wouldn't miss the NATS one little bit.

 

Thanks... The trick with using a blue sharpie to outline the ports and a $2 tool from Harbor Freight to poke down the LIM ports and scratch on the heads made my life a lot easier when port-matching. The surgery on the entrances to the head's intake ports was easy, too. I spent a lot more worrying about it than actually doing it. Good luck.

 

I updated the intake filter a bit tonight - didn't want to use my oscilloscope outside in the rain.

The old setup:



After:





Two views of the Alty intake manifold.

 

I set up the triggered-sweep scope on #4 injector, to see what I could see.

The scope:



And what I could see of the injector pulse:



I could rev up the engine until it hits the limiter - but I couldn't see clearly exactly what happened - the pulse appeared to still be there, but much shorter while the limiter was working. I can't be sure enough to bet the farm on installing my EU, so I'll have to do something else.

What I need here is a simple logic probe that can trigger on a negative-going pulse that lights a LED for a short flash - every time the injector connection to the ECU goes negative. These probes used to be quite common, but I'm off to eBay.

 

Awesome that you got it all figured out. Sounds like a successful day. I need a ride!

 

In regards to your updated intake filter setup have you seen sparks03max info involving resonant frequency?

http://forums.maxima.org/7939656-post37.html

 

Do you have some kind of logger? Consult or OBD2? If so you can just log the injector pulse at redline and that will tell us if it sends a signal or not.

 

Thanks - I did see it - he's always thinking - but I don't think I'm ready for a resonant frequency yet.....

 

Well, that's a thought... I had a couple of OBD2 loggers, but my notebook ate its hard drive, and I haven't reloaded them into one of the other notebooks. I will look into this. Thanks. It may be as simple as just connecting a superbright LED across an injector and bouncing off the limiter a few times!

 

You've been on my private "test track" - we'll save the next ride for after I have nitrous/alcohol installed!

 

You could always switch to an earlier ECU. May be the simplest way to get the EU to work properly. I used to have a 96 maxima and I could not for the life of me get the rev limiter extended. I must have spent like 2-3 weeks trying to figure it out. But then I slapped the EU in my friends 97 max (plug n play harness i had made) we took one run, I created a extended rev map, we then took the car for a test run and it worked almost flawlessly. So in the end I bought a 97 5spd ECU and within a couple runs had the extended rev limit with ease. All it required was moving around a couple of the engine harness wires and the ECU worked with no CEL.


All this is interesting though. I was contemplating trying to design my own IM or to mock up the 07VI to my car. I was pretty sure I was going to go with a custom IM but everytime i tune into this thread it makes me want to go the 07VI route.

 

Thanks for the extra info about using the 97 ECU - at least I know something can work.

You could do the "07VI" mod with not a lot of pain. Get the LIM bolt holes opened up (wider inward about 5mm), find fuel rails that will fit to the LIM (stock 07-08 Alty will fit), cut and glue a gasket on each side of the LIM, use a blue Sharpie to outline the intake ports on the heads, put the LIM in place and use a scribe to mark what needs to be bigger and cut out some aluminum, then both it down. You can also see all the surgery I did on the TB, but that's me....

Wait until you hear about what SurraTT measured on his 09 Maxima engine...

 

Sounds good to me!

 

A few changes over this weekend... first, when I removed the aluminum intake system, I find oil inside the manifolds - I'm getting tired of finding this mess, so it's time to fix it. So I drilled out the PCV valve and hung a small filter in it - and I already have one on the front valve cover.



Rear valve cover:



Front valve cover:



Then I re-mounted all those odds and ends that the ECU still expects:



And we had a little hail last night:




It kinda chewed up the roof - it was an exciting evening here.

 

This is the best car-side workbench I ever had: and it folds up when you're done...