Installed BHR ignition - weird sound
 

I recently installed the BHR ignition upgrade, everything went smoothly and there weren't any issues with installation, but today on the way to the shops...i was cruising at 60km/hr in third (2.5krpm) and notice a strange gargling/Marbles in a can sound.... this sound can only be replicated at engine rpm between 2k and 3k RPM after that it goes away and there isn't any other strange noises.

Has anyone else experienced similar issues? any ideas what its might be?


FIX: Re-purged coolant system and topped it off! this issue had nothing to do with the BHR, except do NOT forget to top off the coolant if you remove that bracket that is bolted into the water pump...

Lets start with the basics...

1) You know that BHR offers telephone support (though I see you're from Australia)?
2) Did you use the recommended ground?
3) Ensure the spark plug wires are secured to the plugs and coils.
4) This probably isn't it, but verify the coils are going to the correct plugs.
The coil order from front to rear is: L1, T1, L2, T2.

1) i sent charles a PM
2) that ground spot isnt available on the rx8, i used the point recommended in the guide in the second last post on this page: https://www.rx8club.com.au/forum/vie...start=105....i scraped the paint off
3) i will check this again tomorrow
4) not this...i hope or much worse things would be happening i assume. (but will check again for piece of mind)

is it possible i damaged one of the connectors from the leads to the coils? would that cause this weird sound...how would i go about checking any damage without possibly causing more damage?
I will also pull the plugs and check for build up/fouling....if i cant find the issue i will install the stock coils and leads and go from there.

2) The American instructions say to run the earth lead to the Brake Master Cylinder but of course that’s on the wrong side for the Australian cars. Fortunately for you there is a spare earth ‘Tab’ on the passenger side near the strut tower at the washer bottle side - just scrape the paint off and use that for your earth point - perfect!

As Ray often cites you have to be careful with the connectors as they're somewhat fragile when making the connection (solid once connected).

Indeed, I was just quoting the OP's own source.

Just sounds like the coolant system to me.

LOL Oh, I believe I know the 'value' of which you speak. ;)

People just aren't accustomed anymore to the level of service that BHR provides. It used to be commonplace but it's now a throwaway society and our expectations have been suitably lowered.

"The 10% will be with us, always." The rest of us truly appreciate BHR's and MM's forum contributions (and products). Keep 'em coming.

Indeed. Many don't notice what was already there until they install something new and therefore have a heightened awareness due to expectation of change. And we've all rushed a job at some point to get to that new expectation.

So much for amateur perceptual psychology. ;)

Yep! It was only after installing your kit that I noticed the gurgling/ticking noises from the heater core because I wasn't playing the otherwise always-on stereo. The engine itself remained smooth as silk right up to 9k.

will update this thread tomorrow, i have a feeling that jeff (MM) is right and its something to do with the cooling system. (recently added the mazmart waterpump and thermostat) so im in no way blaming the BHR product...and i hardly ever use the radio, HiFlite999, the rotary is enough music to my ears! ;)

Charles i understand that you prefer a phone call, but the time difference and international call rates wouldn't make it worth while for me, especially knowing how much the BHR team is on the rx8club forum! :)

Also could you go into what transmission/stationary gear lash is? as i recently had my ACT clutch/pro lite flywheel installed (with HD bearing of course from BHR)

Does anyone know how to change the topic i dont want this to seem like an attack on the BHR product.

Charles how do you recommend purging the coolant system? i have heard mixed stories on how it should be done?

i do it in a similar way, will do it again tomorrow and re-route the ground and check installation...hopefully everything is ok! :)

I had a similar problem on my install. It would seem that while driving at around 2 to 3k you would hear somewhat of a knocking sound. Initially I thought it might be engine knock do to the new install. Under careful inspection it turned out to be one coil wire harness sandwiched between the new coil bracket and the intake tube vibrating (weird I know). Moved things around and noise is gone.

I don't know if I want to set off fire works or play a violin.




JK

how about playing the violin while the fireworks shoot up in the sky...and then BANG. would be pretty dramatic. :)

anyways back on topic, i topped up the coolant (wasnt that bad), re-grounded the coils to the oem ground. checked re-installation of throttle body and intake...all fine. when i have more time (monday PM) i will check the lower half of the install (spark plugs for fouling/carbon build up and proper connection of the leads).

the air control valve for the secondary air pump is making a weird knocking sound at idle! could this be the culprit?

how could i check proper operation of this? i still have my cat otherwise i would just remove it completely!

Oh yeah I was serious. I suspect an increase in IQ or education, also increases one's ability to deceive one's self. Examples abound (unfortunately).

Hiflite999 you make a very interesting proposition.......maybe that's why i cant study for my exams at the moment, my brain is deceiving my self and distracting me from my work! ;)

Has the issue been fixed yet?

checked the lower half of the install and everything was fine (except slight carbon build up on the leading plugs, trailing was fine, what would cause early carbon build up on only the leading plugs? not revving the engine enough?) i didn't change the plugs when i put the BHR ignition in, they where relatively new...i want to seafoam the engine so will put the new plugs in after i do that.

The sound was almost 100% eliminated when i re-purged the coolant system and topped it off...(thanks to Jeff - you were right!). It was just me being forgetful, because when i installed the ignition system i removed that bracket that bolts into the water pump obviously causing some coolant to leak out and air to get in. I will drive it again tonight when i go to the gf place and see if its 100% fixed.

Thanks to Charles for his awesome customer service ;), and to Jeff for alerting me to the possibility that is was the coolant system.

Ok additional update....for anyone that is interested. car hasnt been driven much lately.

I think it may be "gear lash" that CRH originally highlighted. i guess its one of those 'trade offs' that you make when going from OEM to aftermarket.
very happy with my car in its current state, and this strange noise does not seem to have any effect on performance.

Sounds like it's time for a preformance Transmission Spec/balance service to be offered from BHR