RE: 1982 245DL (B21) with Chrysler Ignition.

Current status: Runs fine for 5-10 minutes, then performance starts to degrade over another 5-10 minutes until running extremely rough. Sputters, knocks, spark ping, won't advance sometimes, stalls, etc. I can usually limp the last mile or so home.

Background: My son who does not live with me has used this car for a few years, so minor maintenance had been neglected. I got it from him because of frequent stalling. I changed plugs, cap and rotor because of the stalling and ocassional miss at all speeds. Seemed to be doing OK. I also notices a front wheel bearing whine. It went in the shop for that and a replacement of rear end bushings, seemed fine after that.

The Sunday I was going to give it back to him, it "threw a snit" as above. I quickly inspected under hood for loose wires, etc and didn't seen anything obvious. This snit started after driving streets for about 10 minutes. I was about 1/2 way up a nasty hill. Limped it home, about another 2 miles. Monday a.m. I headed for my mechanics about 20 minutes away. I made it less than a 1/4 mile the it started another "snit", quickly it got to a No Start and I had it towed.

At the shop, much later in the day, it started and ran fine. It did finally go weird in the shop and had very weak spark. Coil was too hot to handle.

So, New coil.
replaced a few wires and split/missing vacuum lines.
Cleaned contacts on ICU
Ignition looked fine on scope at idle and on dyno (My Mechanic is also a CA smog guy).

I pick it up and it seems fine. Got on freeway, up to 65 fine and smooth running. As I started up a gentle hill, a little "flutter" kinda like a high speed miss, but more like fuel startvation. Then started losing power slowed to about 40 mph. Not running rough, just no power. I got off next off ramp. After sitting a light, things seemed slightly better. At next light better still... ot back on freeway and headed back to mechanics. Seemed like classic fuel starvation.

Mechanic replaced fuel filter, almost totally blocked
replaced both fuel pumps (not up to delivery specs) & "sock"
Flushed fuel tank and fuel lines
Swapped ICU with spare on hand.

Mechanic sez it was test driven several hours. Also run on dyno at 75 mph for 1/2 hour no problems. I drove home on Friday pm (20 minute drive) mostly freeway and no problems.

After hitting a dip a little bit hard I noticed the little "flutter" in the engine that marks the onset of the issue above. BTW, this dip was also about 5 minutes from cold start at home. The flutter starts as what feels like a high speed miss. Ran OK for next 5 minutes, then was parked for an hour. Headed off again and started to notice more of the "high speed misses" after about 5 minutes on freeway. Drove about 5 mins more on freeway. Started running rough and stalled at intersection. Got it started and limped a ways...
Swapped ICU with "spare", no change. Limped another mile to destination. Parked for about 3 hours. Started fine seemed to run OK for first 10 minutes (5 mins on streets, 5 minutes on freeway). Got off freeway, running slightly rough, but "kept it moving". Stalled about 1/2 mile from home. Limped home with a couple stalls, and much "coughing, wheezing, pinging, spitting" and other nastiness.

Since then I've dome a few more things:

while in driveway running rough in park---
disabled Lambda-sond by unplugging O2 sensor: no change
unplugged CIS by unplugging "exhaust side" firewall plug: idle a bit weird, but no change in roughness
Swapped ICU's: no change
Cleaned distributor contact with hall-sensor: no change
Cleaned all ignition connectors with CRC QD Electronic Cleaner.
Put shrink tubing and/or tape and liquid insulation on some exposed wires on the "exhaust side" firewall connector.

About 5 years ago I replaced the "firewall/computer" side of the "intake side" harness/connector. At that time, I also replaced the engine harness with one with "soft wires" from another 1981/82 B21F.

At least part of this is heat related. I think the cool down required is about 1.5 -2 hours. I love the way the engine runs for the first 5-10 minutes until everything heats up!!! After things progress from the "first little flutter" to the complete snit, the engine acts almost like one where the timing is badly off. It does not backfire, so it's not like a timing belt jump.

I don't have the money to have any more shop work done. I'm pretty competent as a mechanic having done an engine swap on this and other non-Volvo's. I'm an electronics engineer who also worked as a tech. So, I can handle most anything I think I'll run into here.

I don't think this could be a fuel relay because it would cool-off pretty quickly. I'm not sure about the hall-sensor in the distributor. Could it cause this? What else would cause this?

Any help would greatly be appreciated.

Thanks,

Jon Lovegren
San Diego