Wiring Up The Bosch Gear Reduction Starter

[spider2081]

One of the fastons to the right in the photo. Trial and error

Just to confirm, One of the fastons on the right is where the red wire from the ignition switch "start" position gets connected. Is that correct Tim? If so Can either Faston on the right be used. The single Faston on the left of the photo is not used?

That would be similar to the position of the single Faston on the earlier Magneti Marelli starter solenoid.

[tima01864]

Space is tight near the starter, I could not get the boot on so I left it off. Good move in this case. We had put a multimeter to the spades before install. The single spade on the left was unconnected to the bottom post. The two on the right were connected to the bottom post.
Determined the spade single spade on the left would be correct.
Went forward with the install.( Cylinder head, Manifolds , fuel rail, Timing belt, etc.). Wired the FI. Pre filled the oil filter, Added oil to the engine, Removed sparkplugs, Took the two grounds off the plenum so the injectors woudl not open and disconnnected one wire to the fuel pump. Hooked up battery and ready to prime the oil pump. Key in ignition, Just a click.
Charged battery, With Volt meter checked for voltage to starter and alternator. Good. Checked wiring to the coil. Still a click.
I got my arm under the Intake, had to move the wires out of the way and moved the red wire with the faston to the rigt spades, I used the bottom of the two spades which was accessible.
Engine turned over and finished the task.

[RRoller123]

So we have done Static Fuel Pressure and Leakage test, a Free Engine Rotation test, and charged up the oil pressure and circulated oil through the engine. A Compression Test comes next, and then we can put in the cooling systems and we should be very close to firing them up!

I wonder what expected cylinder pressures are compared to stock, with the 4mm domed pistons installed? I was typically getting in the mid 140 psi range with the stock pistons.

[tima01864]

4 issues so far 1: headgasket alignment 2: Timing belt tight 3: timing belt overlaps the intake cam maybe a 1/16th 4: Starter wiring

[18Fiatsandcounting]

2: Timing belt tight 3: timing belt overlaps the intake cam maybe a 1/16th

For both these issues, the first thing that pops into my mind is that the timing belt isn't quite the right one for this engine. I assume you've checked that, yes?

-Bryan

[RRoller123]

Yes, right belt, and it is on. My thinking is that the MLS high performance head gasket is thicker than the stated spec of 0.060". Even another 0.010" or so would more than double that differential amount needed. It is installed now, so no easy way to measure it.

Pete

[tima01864]

The timing belt may not be quite right, For the 2 L Engine it is the correct number of teeth. I had installed the same belt, A Flennor, Before I rebuilt this beast. It was a normal install with no problems. I guess Gates is the new thing in belts, So that is what I was sold. That being said I really dont know.