Ok see if you lot can help, I have a small turbo Escort Cossy with a GGR chip I have used this chip for over 10,000 miles with no problems until now it has started to misfire when on full boost 18 psi and for a while had problems with boost waving up and down on the motorway in 5 th gear. So I disconnected the amal valve and ran the pipe direct to the actuator and had to set it to 12psi to get rid of the misfire.

I have ran is like this for 8 weeks now as I have not had the time to look at it but today I started to misfire again with 12psi only a bit also you can smell it is running rich.

I think it may be the Map sensor but I don’t know I have ran it with no chip and also ran it with a supper chip and it is still the same, also the other day it would not start but when it did it did not rev and though loads of black / grey smoke out !! so I checked all the electrical plugs and all was fine so tried again and it was fine ??

Any help would be nice.

 

sounds like plugs mate,,, what type you running

 

Thank you gareth for your reply, changed the plugs at last service some 5k ago they are Gen Ford (AGPR12PP) and are Supposed to be long life plug no needing changed for some 25K.

One thing i will say is the coil pack lives ontop of the plugs and i know they can break down from time to time.

 

MAP sensor would give symptoms of your stating problem and the smoke. Shame the car doesn't have one. What it does have though is a MAF sensor. This could be breaking down.

I would advise having the ECU interrogated first...

Plugs could still be fooked as well mate.

 

they do have map sensors

 

There was a known problem with some small turbo escort cosworths with regards
the MAP sensor wiring.
This problem was high lighted on some standard cars but mainly on chipped cars.

Not all cars showed up this problem and it may now be showing up.
Please get a proper fault code/diagnostic done before doing this if NOT already done.

Usually when GGR convert a car themselves, they change this wire and it was
a known problem with ford as they have a finis code for the replacment sub loom.
(dont ask me what it is - talk to Alistair Mayne @ GGR)
This loom consists of a seperate 3 wire loom from the map sensor to the ecu
connector socket. This was usually incorporated into the main loom and
will be hard for non experienced persons to actually see if it has been fitted.



*** EDITED ***

Also checked the multiplugs on the inner wing are in good condition and
do not have water or corrosion in them.

Just another suggestion

 

Hi Simon Thanks for your input

I checked the plugs the other day all was clean and still have the OEM grease on them.

I fitted the GGR chip the car came with the super ship fitted by colins.

I am wating for you to come up with your Plug an play ECU will that fault check all the sensor ? and will it still run the Air con

I Do some work for our local Ford garage but they say they dont have the right code reader to read fault codes on my car they say you need a RS dealer.

STU IF YOUR ARE READING THIS CAN YOU HELP IF I BRING THE CAR TO YOU ???

 

ANY ford dealer using the FDS2000 or STAR tester can read the diagnostic
fault codes from the ECU.
(I help design both these products so I should know )

If they still wont do it, take it to a non franchised garage that has Crypton or Sun
diagnostic equiment. They will have a STAR tester equivalent system code reader.

EEC4 is a pig to work with at the best of times and most garages will just
change bits until its fixed and charge you for bits fitted that you didnt really need.

If you cant sort it, take it to a specialist like Stu - will be worth it in the long run. !

The new EEC4 version S8 (S8E) will be FULLY self diagnostic and ANY pc can read/check this. (Wont be long now !)

 

Come on then are we talking weeks or months ??

 

GGR are evaluating/testing the final version for me.
The biggest problem is trying to get hold of the ecu connector as it is
a custom one specially for Ford.
At the moment, I am breaking old eec4 units and robbing the connector out of them.
Not very good but its the only way to make it plug and play.
Considering getting my own version manufactured but that will be VERY
expensive and although I can see many sales of this version, it will
not cover the new connector cost unless I put the price up drastically
which kind of defeats the point of the product to most customers.

Realistically, This version wont be available before DECEMBER.
There are other NON technical issues to be resolved and these are
out of my hands at this point in time but things are beginning to move !

You will need to get your car sorted before changing the ecu anyway !
I will add you to my mailing list to inform you when things are happening.

 

i would still try a new set of plugs in her

 

Hi simon i took it to ford today they said they canot read any faults as when they have fitted the chip they do somthing to the ECU ?? so they canot access the ECU. Know i think that is Bullshit do you ?
Can you go into some detail abou this MAP sensor wireing ?

 

The chip for a small turbo model is fitted into the ECU's diagnostic port.....hence why they cannot connect it.

 

Yes i know that that is why i removed it before i took it there today, but they still could not read it and also the car did not feel any slower with the chip removed ??

 

Can I be added too?

 

They are talking absolute bollox for a change
The datastream connector is in the passenger kickwell behind a small access panel on most small turbo models and gives full datastreaming so the chip can stay put.

The car wont feel slower as you bypassed the ecu's method of turning up the boost and thus just forced it to overfuel instead

I would still have changed the plugs first.. 25K isnt happening unless you never drive it hard

 

By the way - STU do all those convertions run similar boost levels? Mine cuts at 1.6 bar and I have it set below 1.5 but have no idea about proper level as I have it only listed on car sale document as "270PS Power-paket". It doesn't run boost control.



Oh - and Stu I never got any reply for my PM question. If it was to abstract to answer I'm sorry

 

Stu thank you for you input mucho thanks

Sorry i should say i have chaged the plugs last week still no good, I thought ford were wrong.

Ok what is happending is drive down the motorway and the car cuts in and out like turning the key of but the tacho needle does not drop and some times goes into limp mode but of you turn the ing of then back on it is ok. Also somtimes when you drive it very slow say 1500 -2000 low load it cuts in and out and you can here a relay in the fuse box clicking.

What i have checked is the wireing to the coils air gap on the crank sensor, plugs, fuel filter all wiring plugs.

 

I had the same - it was very very dirty connectors on main ECU multiplug and that for the chip. Take teh ECU out and clean it. It helped with mine. Used Xeramic Brake Cleaner.

 

that sounds exactly like the problem i had on mine, remove the chip and clean the connectors then try it, as i was given this advice and it worked

 

Give it a go in the mornig

 

I had an on going problem for months, changed spark plugs etc and still no joy. I ended up swapping out the ign amp, phase sensor and then crank sensor one by one. It turned out to be the crank sensor. It looked fine from the outside but once i took it off the car you could feel it had gone solid and brittle. Once changed problem cured.

Paul

(Big Turbo by the way)

 

Didn't know that.......

 

I had the exact same problem on my GTI (clicking niose cutting out etc) I know we are talking obviously different cars here but in my case there was water in the fuse box, we shall find out tomorrow if that fixed it but lookin like deffo that cos tried just about everything else

Dunno if that helps as Im not technical at all! but maybe of some use

 

Well, fuseboxes are a common fault on Mk5 RS Escorts, so it is worth checking for dry joints/cracks if all else fails......

 

and fuseboxes are 220 sheets from ford bought one to eliminate my big turbos p1ssin about last summer.