saxo guru advice needed, cant get my head around this!

  1. Newbie Joined: Jul 2013 Posts: 5
    #1
    Im at a dead loss with this and was hoping someone here could point me in the right direction.

    My mate has a 1.1 mk2 saxo (2002) multi point injection.
    Headgasket went on it so i changed it, did the job properly (new stretch bolts, head skimmed/pressure tested, new cambelt/tensioner and all the rest). So built it all back up and it just wont run right.
    Sounded to me as if timing was out, sounds loud when running, runs very rough and barely ticks over, eventually dies. Checked timing, locked cam pulley and flywheel and its spot on, the belt is tensioned right so all that side of things is correct (is the cam pulley on a woodruff key?).
    Plugged ethos into it and pulled code p0300 random multiple misfire, not very helpful.
    Cant pull plug leads seperatly as it has that stupid all in one coil pack, the pack and plugs were replaced with new 2 months ago though. Tested for a spark and they're all sparking. However number 3 plug was very black and number 4 was wet (petrol) 1 and 2 were ok.
    Found the engine runs better with the breather on the inlet unplugged so im now leaning towards it being a fuelling issue.
    Plugged ehtos back in, got the live data up and found at 60 degree water temp its still running open loop. Now heres the strange bit, there is no voltage readings on either lambda sensor, just says 0.00 and when we revved the engine 'fuel system 1' on the live data switched from open loop to open loop fault (fuel system 2 said 'not used')
    Smells like its running very rich, possibly in limp home mode but i dont know how to tell if its running limp home mode or not. Just keeps itself ticking over (extremly rough) with the breather unplugged, not very responsive to the throttle either and when it finally revs up its very stuttery and very loud (like a horrible tappeting noise but louder), sounds like a old diesel almost.

    Previous to headgasket change i did notice the engine was hunting at idle but nowhere near this bad, just like blipping throttle.

    Any help massivley appreciated

    thanks
  2. Newbie Joined: Jul 2013 Posts: 5
    #2
    oh forgot to mention, the coolant system isnt over pressurising quickly and the coolant/oil havnt mixed so im fairly confident the headgasket is holding up.......
  3. Saxperience Hardcore! Joined: Dec 2007 smurfland. Posts: 17346 Ex saxo owner.
    #3
    Dead or dying lambda sensor causing overfueling,likely to be the top lambda sensor.
  4. Newbie Joined: Jul 2013 Posts: 5
    #4
    Would that make it run as rough as it is though? It sounde like a tractor when you rev it up. Is there anyway the timing could be out?? It was locked up when belt was put on and both cam and crank lock up when its timed, anyway manufactuer marks could slip? E.g. crank pulley slip round etc
  5. Saxperience Hardcore! Joined: Dec 2007 smurfland. Posts: 17346 Ex saxo owner.
    #5
    If you`ve locked it up when doing the cambelt & timed it correctly with the marks then you should be fine & yes a faulty lambda will make it run rough.
  6. Saxperience Post Whore Joined: Oct 2007 North-east - Washington Posts: 7311 Clio 182, Fireblade GSX-R 750
    #6
    Does sound like the timings out to me
  7. Newbie Joined: Jul 2013 Posts: 5
    #7
    Timing has being checked, checked and triple checked. Its definitly right (well it locked up on manufacturer locks at least). Still runs like a bag of spanners, runs better with the breather on the inlet unplugged. Sounds very tappety and the noise raises with the revs. Im going to do the tappets tomorrow to at least rule that out but im not holding my breath haha. Possibly could be coil pack shorting to the engine causing the misfire and the noise but the coil pack is 2 months old and I cant see any cracks/breaks etc that could cause the pack to short. Is there anyway of testing it?
  8. Saxperience Post Whore Joined: Sep 2007 Someones Bumhole Posts: 5721 Mk2 16v Desire
    #8
    You need to reset the tappets dude on the 8v's they could be a country mile out after a HG change seems as you take them off, start there.
  9. Newbie Joined: Jul 2013 Posts: 5
    #9
    I think youre right pal, I whipped the rocker cover off earlier and just had a quick pull at all the rocker arms and 2 (obviously the ones that happened to be 'on the rock') were a mile out, easily a 1mm+! Im going back up after work to set the clearences, its 0.2mm inlet and 0.4mm exhaust, right? Ill let you know how I get on tomorrow, thanks for the help everyone. Just out of interest how does removing the rockers put the tappets out of adjustment? As the adjusters arnt touched when removing..