Technical 1.6 ie Engine stalling and hardly running

[purf]

Hi again...

I'm being plagued by an engine issue. The X was running great until a couple of weeks ago the timing belt jumped 4 teeth.

The car ran and seemed to have lost 20% power. It made some strange noses when the timing slipped. After the timing was returned to normal it drove the same. Lack of power and bogging down at low revs.

I couldn't figure out why the timing jumped until I stripped the top end and found water leaks from the inlet manifold had ingressed into no 2 and 4 chambers.

This was either due to loose manifold studs or a cheap manifold gasket which had a copper ring rather than a rubber seal around the water passage as the original gasket.

I cleaned the valves and head and while I expected the valves might have been damaged they seemed fine and there was no evidence of any contact.

I lapped the valves and refitted the head. After battery was disconnected it was a total pig to start. Eventually started with full throttle. I let it idle and the ecu learn and took it up the road. It seemed better but stalled when I stopped. on restart it idled for a while then became impossible to pull away unless full throttle was applied.

It ticks over but the slightest blip of the throttle causes it to stall. After trying various things it now struggles to start and when it does can barely idle.

I have replaced the coils last year but with a cheap aftermarket. Also the only sensor I have not changed is the crank sensor. I suspect both.

Will refit the original coils but the reason I changed them was due to very similar symptoms. When the HG had gone....

It has not overheated at all and I have just fitted new hg etc after inspecting the valves.

HELP!

 

[sledgehammer]

What type of fuel pump do you have? Is it the x19 manual pump? I had intermittent running problems with both my X19's, fuel pump failed. I now have an electric fuel pump.

 

[purf]

It's electric in line at the top of the tank. Aquired with engine. Seems to have plenty of fuel at the throttle body. Might be worth a try I guess... Following crank position sensor.

It has run fine for months with the existing electric fuel pump.

I have read about the height issue with fuel pumps.

I'm also going to swap the lambda as it might have got water on it from the manifold gasket leak...

 

[purf]

I messed about with the fuel filter last night. Didn't look too dirty but seemed to have made a little improvement. It ran and revved if I was gentle but as soon add I floored it or was quick with the throttle, it would bog down and stall. Also under load it needed revs to move.

I'm also suspecting the lambda sensor so I will change that tomorrow for a spare one I have.

I wonder if the manifold gasket water leak has got to the lambda?

 

[sledgehammer]

It does sound a bit like an inlet manifold leak. Had that happen to me couple of years ago. Wasn't too bad when it cooled down and I managed to limp home, ran like a pig if you tried to accelerate too hard.

 

[purf]

Changed the fuel filter. Changed the lambda sensor. Swapped the Throttle body including all sensors, Tps, idle control actuator. Tested fuel pump. Still no change...

Crank sensor should arrive early next week. I think its unlikely that will be it though.

Dropping it at a local Italian specialist on Monday... I give up!

 

[purf]

Changed the water temp sensor with a spare just in case. Also the coil pack. No change...

 

[purf]

Just about got the car to the Italian Specialist round the corner.

My latest thoughts are that the valve clearances need adjusting after I've lapped the valves and possibly the manifold face of the head needs machining flat?

 

[sledgehammer]

Hey, did the italian specialist get your motor sorted?

 

[purf]

Hi yes I thought I had updated!

The garage concluded it was the cam timing. Italian Spares and Repairs - Did a great job and quick too. I cannot understand how it happened as the factory marks were lined up perfectly. I have used the marks previously but perhaps did not have them lined up 100%. It may not have the original Camshaft fitted?

I need to check the part number on the camshaft as I suspect it might have an X1/9 item fitted???

Its now running better than it ever has with this engine as it was never quite 100% before. It would often stall in reverse or when cold and didn't like to idle along in traffic at all. Now its much more composed and sounds spot on too.

New timing marks have been painted on and its been in use every day since.

The radiator fan has not worked for about 6 months. I'm trying to sort it but with the VW radiator it doesnt really need it! Also the headlight motors are misbehaving again... oh and the horn doesn't work... and I still need to fit the new springs at the rear...