Troubleshooting gas engines is usually checking compression, ignition, and fueling, in that order. I had checked cam timing before installation, and the cranking noise indicated that we had compression, so I crossed that off. Looking at ignition, I had an earlier problem in that the engine, as purchased, had no coil. I bought a coil on eBay, and when it arrived, I found that none of the output posts were numbered. So, I went to the local Advance Auto, and found a Haynes manual for the '03 Focus that had been opened and (obviously) thumbed through, and looked up the ignition wiring. I know, it's a bit tacky, but they got my alternator and starter business, so they're not suffering too much.
Haynes was useless. The advice was that if the coil wasn't marked, make sure to document the connections before removing the old coil. So, I asked Bostig, and they supplied me with a photo of a crated Zetec that showed the correct wiring. I went back to that ticket, and confirmed that my wiring matched. I don't have a spark tester, so I tentatively crossed off ignition.
Next, I carefully disconnected the incoming fuel line. I had obvious pump noise when I turned the key, so I was surprised to see that the hose was dry. I tried the pump with the hose disconnected, and - no fuel. Aha! I went under the van, and reversed the wiring to the fuel pump. I then re-tried the pump, and got a good flow of fuel into a can I'd placed. Buttoned everything up, and went back to startup. This time, the engine fired right away, and after solving a final issue (see below), I let it run. It slowly settled down as I watched its vitals on the Elmscan display (actually, the component on the laptop is called OBDwiz, but Elmscan sounds better).
The fuel trims varied widely for the first five minutes, as the engine probably tried to adjust to sticking injectors, then settled down to a good 5 - 7 percent (short). The long trims came in at 24%, which is high, but influenced by the volatile short trims and should, I think, settle down.
We had a problem on the first start. The engine started to howl right after it smoothed out, a noise that could only come from an accessory, which I proved by removing the belt and running the engine by itself for a couple of seconds. The culprit turned out to be easy to find. Somehow, the power steering reservoir had drained enough into the system over the past few days to bring the level below the height of the intake hose to the pump, and it was running dry. We went downtown, bought a pint of PS fluid, and filled it back up. Problem solved, except that at the end of the initial 20 minute run I seemed to be hearing a fair amount of noise from the pump, despite a full reservoir. We'll monitor this today.
Next: coordinating the drain/refill of the cooling system after the around-the-block run, which I hope to do late morning today.
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