Okay, I'm nearly at the end of my rope with this and am hoping someone will have a brainwave about it.
The background: I have a '97 D1 that was originally auto (ZF). Last year I converted it to manual (R380) and in general it runs perfectly. But there's one issue, in that under certain conditions (below) the engine just flat out dies.
Starting, shifting, and driving are all fine. But if you downshift (especially if doing so really revs the RPM) then push the clutch in, about 10% of the time the RPMs drop immediately to zero and dies. I've also noted it will go into this mode if you've been just using engine braking on a gentle downhill run (no downshift, just basically coasting). Popping the clutch generally restarts, otherwise it kicks right over with the turn of a key. On the road it gets 16-18MPG and the engine is absolutely smooth.
What's been done so far: IAC, MAF, and TPS swap (I have good spares for all 3). New fuel pressure regulator. Plenum chamber removed, resealed, and cleaned. All vacuum lines renewed and checked. Plugs/wires new last year (3k miles, no more). Air filter also new, etc. Working on replacing the fuel filter (age unknown, probably original) on the off chance it's involved, but one fitting is seized and I haven't gotten enough PB into the fitting to loosen it yet.
The shop that did the swap is very good, and they're scratching their heads. I've talked with a few other folks and no one seems to have a handle on this, so I'm looking for weird things that might have been missed. I'm pretty sure the shop put the proper spacer on the crank sensor, and the ECU is from a manual car thanks to another LRO who sent one my way a few weeks ago.
So...ideas, please before I give it to someone as target practice?
Thx,
dj
The background: I have a '97 D1 that was originally auto (ZF). Last year I converted it to manual (R380) and in general it runs perfectly. But there's one issue, in that under certain conditions (below) the engine just flat out dies.
Starting, shifting, and driving are all fine. But if you downshift (especially if doing so really revs the RPM) then push the clutch in, about 10% of the time the RPMs drop immediately to zero and dies. I've also noted it will go into this mode if you've been just using engine braking on a gentle downhill run (no downshift, just basically coasting). Popping the clutch generally restarts, otherwise it kicks right over with the turn of a key. On the road it gets 16-18MPG and the engine is absolutely smooth.
What's been done so far: IAC, MAF, and TPS swap (I have good spares for all 3). New fuel pressure regulator. Plenum chamber removed, resealed, and cleaned. All vacuum lines renewed and checked. Plugs/wires new last year (3k miles, no more). Air filter also new, etc. Working on replacing the fuel filter (age unknown, probably original) on the off chance it's involved, but one fitting is seized and I haven't gotten enough PB into the fitting to loosen it yet.
The shop that did the swap is very good, and they're scratching their heads. I've talked with a few other folks and no one seems to have a handle on this, so I'm looking for weird things that might have been missed. I'm pretty sure the shop put the proper spacer on the crank sensor, and the ECU is from a manual car thanks to another LRO who sent one my way a few weeks ago.
So...ideas, please before I give it to someone as target practice?
Thx,
dj
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