Hi, I have just put in a "new" 4wd Engine in my Sapp. Cos, and have passed 3500 problemfree km.......but now it has developed a problem .

It starts fine from Cold and idle is sometimes ok for 5-10 sek (still cold), but then it can start going up and down in rpm ( 400-1100rpm), and then back to almost normal and back again, also when trying to go it will sometimes stall or even when putting on the light it sometimes drop the rpm or also stall........when getting warm it seems to settle at around 800 rpm but with some misfires...if stoping in trafic or after a run it sometimes idle ok for 5-10 sek and then the misfire is back .

And when driving on boost and some load it seems to be ok, but on "part throttle" (no load) there is some small Hessitaion/misfire and when lifting off (engine braking) you can really feel some Hessitaion/misfire !!!

I have new ACT, CTS, TDC, TPS, plugs, leads, gp A coil....and the car is running 4wd engine, 4wd loom with 2wd ECU and TPS (wires are reversed ), Ahmed Bayjoo stage 3 chip, 803's, 3 bar map and so on.....

So can anybody give me some good advice where to start....

 

I had a similar problem with the idling, and found that the idle speed control valve was sticking. When the revs start jumping up and down, pull the electrical plug off the idle speed control valve and see if it stops jumping around. If it does, then just clean the valve and this could solve your problem. It solved mine. This also might contribute to your misfire.

Worth a try.

 

Hi....the ISCV seems to be ok.....

So please .... any advice would help

 

Have you checked for any fault codes???

 

Well...yes...I have tried this morning on my way to work, to "pull"out some fault codes...but if I follow the instructions (turn on ign or start the car) no codes are there, only at steady light for a few seconds, even though the car misfires .......but then I tried to drive ...and the car stalled...and then suddenly there was a code 1.3 ..mismach between phase and tdc sensor........ but I dont know if this is a correct reading, as it didnt show any codes when going on road and on idle, even thou it misfired and so on.... ??????

 

the problem is it'll only show codes whilst they occur, the ecu has no memory to store the codes........

So you're getting a 1+3 are you???

Phase synch fault........

This is the relationship of the Crank sensor and the phase sensor.
So i'd start by double checking them both.
Make sure they are set up correctly.
Reletive position to each other, Gaps, condition, resistances etc.......

 

Is it an L6 or L8 ecu you're using???

IIRC the codes are very slightly different between the 2............

 

It's a L 6

And I will check it tomorrow....... I will get back when I have checked it...

 

Just had a look......

1+3 code is the same for both l6 and l8......

Mismatch between Phase sensor and Crank sensor........

 

Sorry to jump on post but where is the ISCV. I wannacheck mine

 

Throttle housing........

has an electrical plug on.

 

Hi...I have now looked at it and found that the gab at the phase sensor was .55....it should be .2 - .3 (ref. the Cosworth manuals......but in the haynes tech. spec. it says that the gab should be .3 - .4....????) ...I tried to adjust it but it could only be adjusted to .4 ?? ??

Has anybody had this problem ??? and what could be the problem...?

I now modded the bracket to the sensor and set it to .3...and are now going to work, testing it on the way.

I will get back later with the result .... good or bad...

 

Dont forget though, this is why it is so important to have the sync between the crank sensor and the phase sensor.

If they are installed incorrectly (not set to the dizzy mark on the body) then they will be slightly out and this would be reflected in the gap, as the sensor and the lobes would be slightly misaligned???

make sense?

 

yes...but I'm a bit confused that I could'nt adjust it as it should, ref the manuals....

 

Thats my point........

If they are timed wrong the cam lobe will be in a different position to what it should be, hence the gap will be wrong........

 

I think I see what you are saying, But I have checked that all timing marks are ok and spot on.....

but when you meassure the gab....the two "cams" on the dis. shaft should be .2 to .3 from the phase sensor, but I could not get the gab under .4.... only after I modded the adjustment..

I find that strange that it is not possible to get the gab right...

Anyway ... after a test ... it seems that the problem is still there... only difference is that I do not get any more fault codes.... soooo..

 

I have now completed the resitance tests...and I found that in test 21 "ing. Amp. module to ground connection" ... it says that it should read 0.0 to 0.5 ohm .... the actual reading is 6.9 ohms ... ..could that give me these problems

Also I found that the 803 injectors are about double up in ohms compared to the std injectors...I didnt know that..

 

Have you checked the earth points?

There should be 2 IIRC, one goes from the amp loom directly to the amp mounting, then from here to earth.....

 

Hi...I am not sure if I understand correct....

Do you have a pic or drawing...?

 

Unfortunately i do have lots of information that could help, but i cant get access to it all as its on another computer, and i dont get much time either...Sorry

basically there's an earth from the loom (amp connector) this has to be connected the amp sink first, then a second earth goes from it to ground.

If you look at a wiring diagram you'll see what i mean...try the technical essays section........

good luck

 

ok...I have checked the connections, and there are pin 31 (brown wire) in the amp. plug, and its ok (earth), but that it....there is no external wire to earth,...only the brown (amp plug pin 31) ... loom is a 4wd

When I look at the wiring diagram 1A (Ford sierra Cosworth ´88) ... I only see one eart wire (31-29 BR)....and that one is ok....

I also tried to change the amp as one of the meassurements looked a bit strange...... and I will test it later to see if it has changed anything...

Thanks for you help

 

Send me your Email, and i'll send you some stuff when i get a chance......

might help.

 

You got PM

 

Havnt read half of that

but reading ur first post, i had a missfire on my cossie, sometimes would run fine then sometimes would missfire, hold back etc then be ok etc etc

Turned out to be the inlet plenum gasket had split causing an airleak!!!

Might not be that but symtoms are similar!!

 

....ok... I'm almost out of ideas, so I will have a look, how will I be able to check that....???

 

You can buy stuff called 'Easy start' its in an aerosol can.

If you spray this around the intake (gasket area), if there's a leak the revs will go up........

 

Ok, I will have a go this weekend and get back with the result.....thanks

 

have u sorted it out? have the same problem or similar problem on my saff 4x4.have also changed pretty much everything not the wiring bit for the map sensor and ign.amp

cheers
Geir

 

Hi...I have not yet found out..... .... and it will be a while before I can work on it again..due to my job...but I will hopefully have a look at it again next week...

 

bttt

 

have u sorted it out

 

Having just read you entire problem and everyone else's reply, i can confirm that my 4x4 saff cossie is doing EXATLY the same. I have changed everthing, all the sensors, engine loom, ECU you name it. I have resorted to taking the entire plenum housing/inlet manifold off, today and just re sealing the whole thing, it's the only thing left to try.

Does your idle ok, but slow if you dissconnect the ISCV? Mine does, but it does stop every now and then. It's quite driveable, but you cant really cruise along. If i just change down and leather it, it's fine. Try letting yours idle, with the ISCV dissconneted, and take a vacuum/boost pipe of, like the one to you amel valve, and see if the engine changes not or anything, because it should and mine doesnt, so im going down the "air leak road" I'l let you know if this cures my problem when i have done it.
Bye the way, the plenum is a pig to get off!

 

Hi...sorry for the long delay ...but I did not find the problem before the car was put to sleep for the winter.

Hopefulle I will be able to get on with the fault finding soon, as I have been doing alot of other stuff to my car until now, and I will get back when I get on with it..

 

Hope you get it sorted , as i have same problem with my escos

 

Got mine running again Map sensor was knackered

 

hi...I have still not found out, but I have booked my car in for a tune up so hopefully they will find something, as I have given up ...

I will get back when I HOPEFULLY find the problem....

 

Fook new 3bar map sensor was knackered too

 

so are you sure that it is your map sensor who is the problem... ?

 

What made you suspect it was the map sensor???

Did you get a map sensor fault signal???

 

Tried another one from my mates saff , worked perfectly