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I just recently bought this 240 turbo, and am not really that familiar with 240s -- The cars I know better are the 700-series. So, I'm throwing this problem out to the listmind with the hopes that one or more of you kind folks will be willing to offer advice.
It all started when I discovered that the insulation was gone from the wire that runs to the temperature sensing unit, which is used by the CIS fuel injection, and which is located under the intake manifold. The car was running fine, but suffering from terrible gas mileage (like 13 to 14 mpg), so I decided that I had to eliminate this sensor as a possible culprit. Just to get my hands on the sensor wire, though, I had to remove the intake.
Rather than replace the wire, I used a piece of shrink tubing to cover the bare strands, installed a new intake gasket, and resecured the intake manifold.
After doing this, I started it up, letting it run for a few minutes. It was idling fast (about 1300 rpm), but a single blip of the accelerator brought the revs down to about 900 or 950 or so, and it idled smoothly, although it surged mildly (the surging is something it's done since I bought the car). I took it out for a drive, and it performed fine, but after parking it and putting the transmission in park, I noticed that it was idling very fast -- about 1800 rpm. Blipping the accelerator had no effect. Stopping and restarting the engine had to effect, either. So, I turned the car off, and did other things.
A couple of hours later, I started the car and it no longer idled fast. The cold start circuit was no longer operating, either, I suppose, since it settled down to a very rough idle at about 900 rpm. The engine repeatedly stalled, and required that I keep my foot on the accelerator to keep it running. Once I got the car moving, it drove normally around the neighborhood, except for when I pulled up to a stop sign, at which time it promptly died again. This sort of behavior continued for a few more minutes: every time I'd be doing something with my foot off the gas, the engine would try to die. Then, after several minutes of this, it began to idle without needing my assistance, but it was a very rough idle. And this is where it stands.
I am thinking that perhaps, somehow, I may have screwed up getting the intake manifold seated on the new intake gasket right. I doubt it, but it's one of the things I'm gonna check. Maybe I have a bad vacuum leak that I've missed. I kinda doubt that, too, but I'll check it as well. Perhaps one of the turbo hoses blew partially off? When I took it out for the test drive, I punched it a couple of times, maxing the boost on at least one occasion. Maybe one of the hoses popped loose...
I dunno. It's dark and I'm tired of messing with it. I'll take a fresh look at it tomorrow, but if you might have an idea or two, I'd love to hear form you.
Best,
Michael McBroom
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