Hi,
Ok well a fairly large fail, but most are very easily solved:

Noise - 100DB, need to be 99DB - Solution, DB killer will be tried.
Emissions - Long way over See below

Small things:
Need another bit of writing from manufacture of plastic tank
Fuel rail feeder needs a small bracket on
Fuel filler cap needs tethering
Need proof of using the correct flexi hose fitting - Getting a spare one to go and show them
Bias Bar needs adjusting, Rears locking up first although he was happy with my way of locking it off
4 Exterior projections, Oxygen Sensor on a boiling hot exhaust , front grill aperture and rear edge of jk composite seats, Front Wings need trimming.
Stamped VIN number wrong side of engine bay - oops
Headlamps adjustment
Rear fog lights - mine come on with side lights, needs to be with dipped, simple fix
1 Suspension bolt not being long enough - oops again
Lambda Wiring through bodywork needs a grommet
And 2 bits of wiring that need cable tying up - Would have done yesterday but knowing we failed, thought was best to get it home.
One of the rear wheelarches needs moving a little, too close to the wheel.

Anyway, not too bad, at least its just fixing those bits for the retest, however worried about emissions.

We need to be at 2800rpm 0.2, we were 0.7 at start of day, then after a lot of warming up, down to the 0.5 region.
At idle needs to be 0.3, we were .4 or so....

I have a robin hood exhaust and Cat, It seems to me like those sort of figures seem that the CAT isn't working at all, i have been told the CAT needs to be at 600C to work, all i could test was external cat temp of 170C.
I have spoken to Atspeed who set the car up, they don't check emissions when on rollers so don't know whether CAT was working on the rollers. And they need more info than just Carbon levels and i've managed to loose the print out as i only really concentrated on the Carbon levels.

Has anyone with 1.8 Blacktop zetec had similar emissions problems?

Retest booked for 11th August, however this is just to secure a spot, if i don't manage to solve the bits, i'll be postponing it.

Thanks in Advance

EDIT: Oh and it weighed 560kg although its probably wrong

[Edited on 28/7/11 by eddie99]

At least its a list.

What do you mean by correct flexi hose fitting ?

Apparently people are using the wrong fittings, I.e. using concave fittings instead of convex, It was because we had a small leak at one calliper, tightened it up and all ok but he said thats he's aware that people are using wrong fittings and wants to check its convex.

The emissions sounds as tho' it's simply setup up a bit rich, what's the management system on it? Either that or lambda sensor not working/not connected. If you had a genuine 0.7CO b4 the CAT I would expect the CAT to pull it down below the BETS figures. Highly unlikely that the CAT isn't working if the engine is all up to temps unless it's old or knackered, I've never come across a new CAt that doesn't work.
If you have a method of adjusting mixture on the management make sure you have a way of returning it to existing settings (or you've wasted a rolling road session) & then lean it off a little at low throttle openings in the 900 - 1300 & 2500 - 3000 rev ranges & that should sort it, but unless you have a ready way of adjusting mixture whilst on the machine get a MoT garage to run a standard BETs test on it b4 you take it.

better get mine booked before it gets any harsher

Remember fog light needs to come on with BOTH dip and mains.

quote:

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Originally posted by Macbeast
Remember fog light needs to come on with BOTH dip and mains.

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Hi Ed,
Not too bad a fail that. I failed emissions with a 2.0 Zetec on Bike TB's with Megasquirt. Passed at fast idle but at natural idle mine was 4.98%!!!! All I did was lean it out at idle and re-checked at fast idle. Passed with no problems 2nd time round and as soon as it had I switched it back to original mapped settings.
What ECU are you using?
Matt

Omex 600 mate

IVA retest today, Failed on 3 things:

Brakes - got to be something wrong with my brakes as bias is fully to the front and its still locking up rears first. I've checked master cylinders and they are the right way around etc...
Dominator headlights not having the correct beam pattern.
Fuel tank being plastic - I provided some documentation with it and got the manufacturer to say it was designed for road use which is what i was asked for at the first test. Well provided that and they say it needs FIA or TUV or the likes approval. So basically - i'll be swapping it to an ally or steel tank.

I guess i got the long list down to 3, Emissions failed at first, but tweaking on the laptop got it through

Oh well..... I guess back to the garage tomorrow and change it all around, am at north weald on Sunday so want to get the brakes sorted for then......

quote:

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Originally posted by eddie99
IVA retest today, Failed on 3 things:

Brakes - got to be something wrong with my brakes as bias is fully to the front and its still locking up rears first. I've checked master cylinders and they are the right way around etc...
Dominator headlights not having the correct beam pattern.
Fuel tank being plastic - I provided some documentation with it and got the manufacturer to say it was designed for road use which is what i was asked for at the first test. Well provided that and they say it needs FIA or TUV or the likes approval. So basically - i'll be swapping it to an ally or steel tank.

I guess i got the long list down to 3, Emissions failed at first, but tweaking on the laptop got it through

Oh well..... I guess back to the garage tomorrow and change it all around, am at north weald on Sunday so want to get the brakes sorted for then......

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0.7 on rears, 0.625 on fronts! Bled the system yesterday...

Why are dominator lights still getting failed. They throw a flat beam and it clearly says in the manual that a flat beam is acceptable?

... and why didn't they pick it up on the first test?

They didn't pick up on dominators at first test because i had other fatter proper ones on but the adjustment mechanicsm was slightly broken and made it a pig to change, so i got hold of some dominators and fitted them...

Section 25 note 4:

"Headlamps producing a flat dip beam are acceptable, and
will not have to meet the aim criteria for “break point”"

I think the brakes are sorted **touch wood

The master cylinder push rod out of the front master cylinder had bent , not sure what caused this but this definitely wont be helping the fronts lock up first... Anyway borrowed a master cylinder and bias bar off gavin174 and its all back fitted.... Need to bled the brakes tomorrow ready for North weald Sunday.....