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I'm getting some unusual stumbling at part throttle, mostly noticeable at lower RPM. Feels like missing, or extreme timing jumps? Above 3K RPM it smooths out, and full throttle 16PSI romps are drama-free. No smoke or excessive fumes to indicate anything is amiss. Tach needle is rock steady during events. Idle is maybe a *little* off, just a bit rough, but barely noticable?
Short synopsis of my woes up to this point:
Took a 5hr trip recently, water pump bearings / shaft seals failed on the way. Engine got hot. On the return trip, got a split in one of the heater core hoses, and a small external breach in the head gasket cooling passage - engine got hot again. Made it to destination both times by topping off fluids periodically. Engine was still running fine when I parked it.
Sat for a week while I got a head gasket (Cometic 0.027" MLS gasket.) Started it up and moved it into position - engine ran fine. Replaced head gasket, exhaust manifold gaskets, turbo oil return o-ring, intake manifold gasket, valve cover gasket, injector O-rings, serviced TB and replaced gaskets. One bit of bad news - an exhaust stud broke on reinstall. I managed to get a short stud into place and locked it down with one the spark plug wire shields. No detectable leakage or odors here, seems to be holding.
I can't seem to find any vacuum or boost leaks, and spark seems to be making it to all four cylinders. The distributor did come off the back of the head, and was retimed to 12°. Cam timing is spot on. Problem doesn't seem to be related to the hall sensor or wiring or I would see tach action, correct? The power stage is less than a year old, grounds seem to be in good shape...
Any ideas what to probe next? My wagon is prevented from returning to its natural habitat (the IKEA parking lot) until I can sort this out.
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