My issue was caused by Essex autosport putting rubber washers on my knock sensor. All evidence now points to that. I can’t prove it was them, but there is no other point that this would have been done. This was to solve mapping issues that were a weakness of the kit using the lotus ecu.
With the emu, you will be fine. Does the kit come with the intercooler? I wouldn’t supercharge without it. Even better, charge cool it
No , no intercooler it’s the standard katana kit
That at least gives you a good base with all the parts, personally I don’t see an issue running them with no intercooler, they just have to be mapped correctly. As previously stated the original maps were suboptimal sadly
So the car went back in to Hangar 111 to get the EMU fitted and to be mapped.
On an initial run before fitting the Wideband lamda and EMU, they noticed a rattling noise - 2020 continues to kick at every turn…
They think its either the exhaust sprocket, inlet controller and/or timing chain (although its less than 1500 miles since the engine was put back together with a new bottom end.) They said they followed the Toyota guidance and there was no play or issues with the timing chain then… I also did not notice a rattle on driving it…
One day I’ll get a car that works…
Nightmare mate, did they say when the rattle noise occurs?
It’s not the issue I had with VTEC disengaging is it on gearshifts or decel? Every 2zz map I’ve seen so far has got this ‘issue’, but it doesn’t seem to make the rattle noise on all cars so not everyone is aware.
They said it was a rattle when engine warms at raised revs (not high or tickover) - but they haven’t put the EMU on yet - this was just an initial run to see where it was…
Ah OK, not that then. Hopefully it’s nothing mate - so many possible sources of a rattle in the engine bay before you even get to thinking about engine internals.
They think its either the exhaust sprocket, inlet controller and/or timing chain… so we will see - but I am really fed up that I spent all that money on a new bottom end, and less than 1500 miles later, there is another issue…
I’m not surprised.
andybond do you still have the suspected VVT sprocket rattle on yours?
Not convinced mine is a VVT sprocket rattle. It only occurs for a second on initial start but if I stop and restart the engine that day it doesnt happen again …
Mine has a rattle around 5000rpm that I’m pretty certain must be the VVT sprocket - going to fix it over the winter…
So my story continues… and bad luck
New parts to try to eliminate the ‘rattle’ arrived at H111. Before starting, they decided to drain the oil. On taking out the magnetic plug, there were some metal shards stuck to the plug 
Further examination revealed that one of the big end main bearings has gone 
So on a 1500 mile engine, a main bearing has gone - who knows why or how - H111 will investigate in January…
FFS 
I’m struggling to remember where the 1500mile engine came from, was that a second hand block you bought after the initial issue?
No… brand new from Toyota… the 1500 miles were me running it in… (carefully I might add)
That’s shocking. I’m gutted for you, you’re doing everything right… no reward.
Must be some warranty on that for you?
Think its only parts from Toyota, so H111 will have to see what options are… but this isn’t down to me, I know that much. I feel for H111 if Toyota has suppled them a duffer, but who knows why a big end main bearing has gone so quickly…
quick update - Looks like Toyota sent a duffer to H111 - they have replaced under warranty, but don’t cover labour. Hangar 111 are installing the new block etc and will run in the engine on the dyno at no cost to me. Then finally installing the EMU Black (3rd time lucky ?)
Thats a step in the right direction!
Great news, fingers crossed we’re heading forwards now 