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  1. #1
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    It won't start, it won't idle.

    After sorting out the clearance issue with the plenum chamber and the alternator I re-fitted the plenum chamber.

    Went to start it and it fired up but as soon as I let go of the key it died, Tried starting with a bit of throttle and it runs but doesn't sound right. When I hold the idle at 1000 rpm on the throttle the AFR's are 18+ and hunts between 500 - 1000 rpm, when rev'd to 2000 rpm the AFR's are normal (14.7-15.0) and the hunting goes but as soon as you let go of the throttle it dies.

    It's running the same ICV as with the ME7 manifold and it can be heard buzzing when the ignition is on, I tried giving the car some idle by adjusting the butterfly stop screw, all that did was make it idle at 1000 rpm for a few seconds then it would climb quickly to 3000 rpm.

    Has anyone any ideas ?

    Thanks

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, B5254T ( S60R internals in a 850 block ) ostrich 2.0 , VXR injectors @ 3.8 bar, K24 turbo with a 6+6 compressor wheel, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

  2. #2
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    What ecu are you running mate? You tried any others?

  3. #3
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    Air getting in somewhere?

  4. #4
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    Quote Originally Posted by M-R-P View Post
    What ecu are you running mate? You tried any others?
    I'm running the COP ecu so I can't swap it over.

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, B5254T ( S60R internals in a 850 block ) ostrich 2.0 , VXR injectors @ 3.8 bar, K24 turbo with a 6+6 compressor wheel, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

  5. #5
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    Hmm... As above, do the usual checks for leaks etc and start messing with the map.

    You've not got the throttle on backwards or anything silly like that have you?

  6. #6
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    I'm going to remove the manifold tomorrow and check the face that bolts to the head to see if it's warpped when it was welded.

    I mite make up 1.0 mm EPDM gasket if the manifold is slightly warpped.

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, B5254T ( S60R internals in a 850 block ) ostrich 2.0 , VXR injectors @ 3.8 bar, K24 turbo with a 6+6 compressor wheel, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

  7. #7
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    Have you sprayed carb cleaner around the manifold to see if it's leaking?

  8. #8
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    Quote Originally Posted by M-R-P View Post
    Have you sprayed carb cleaner around the manifold to see if it's leaking?
    The only when to keep it running is to tickle the throttle pedal as soon as I take my foot off the throttle it dies.

    I could have done with an assistant

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, B5254T ( S60R internals in a 850 block ) ostrich 2.0 , VXR injectors @ 3.8 bar, K24 turbo with a 6+6 compressor wheel, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

  9. #9
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    Might be able to pop in on my way home from Portchester tomorrow evening if that's any good?

  10. #10
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    Sounds like a leak at the manifold gasket to me, we had a similar problem on an MGB GT and as you've described Rob, the only way to keep it running was by tickling the throttle and as soon as you let it go to idle it died.
    I did try to put this post up yesterday but the net was messing about and found this morning my was not hear, hope you get this sorted easily mate.

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
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  11. #11
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    I had a similar problem it was down to the butterfly sticking on gook in the intake. I gave mine a polish inside which helped but it still did it and turned out to be a small air leak as well. The intercooler feed pipe wasnt tight enough. You may have disturbed a vacuum pipe somewhere as I did as well with my big clumsy hands! These cars are all pipes and just one off shuts it down!

  12. #12
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    Just a thought - Has the throttle cable somehow slipped or become ill adjusted on your homemade throttle body part?

  13. #13
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    They be the problem.



    I would have expected 1.0 mm of warp in a cast aluminium manifold but it's warpped upto 3.0 mm so I'll have to take it along to the machine shop to get it machined true.

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, B5254T ( S60R internals in a 850 block ) ostrich 2.0 , VXR injectors @ 3.8 bar, K24 turbo with a 6+6 compressor wheel, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

  14. #14
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    Still more fettling needed,
    will it never end?
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    Quote Originally Posted by oblark View Post
    They be the problem.



    I would have expected 1.0 mm of warp in a cast aluminium manifold but it's warpped upto 3.0 mm so I'll have to take it along to the machine shop to get it machined true.
    That would do it. Has it warped through the heat of the welding?

  15. #15
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    Quote Originally Posted by oblark View Post
    They be the problem.



    I would have expected 1.0 mm of warp in a cast aluminium manifold but it's warpped upto 3.0 mm so I'll have to take it along to the machine shop to get it machined true.
    Ahh that would do it, no gasket was going to fill that. A lesson to be learnt by others to machine the flange true after welding then

    Current Volvo's 1995 854 Gul T-5R 1996 855 Olive T-5R 1997 855 Olive AWD 1999 V70R AWD and 2005 XC90 D5 AWD
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    oblark (Tuesday 11th August 2015)

  17. #16
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    Quote Originally Posted by stribo View Post
    That would do it. Has it warped through the heat of the welding?
    I would say yes

    Quote Originally Posted by MoleT-5R View Post
    Ahh that would do it, no gasket was going to fill that. A lesson to be learnt by others to machine the flange true after welding then
    Every day is a school day

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, B5254T ( S60R internals in a 850 block ) ostrich 2.0 , VXR injectors @ 3.8 bar, K24 turbo with a 6+6 compressor wheel, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

  18. The Following 2 Users Say Thank You to oblark For This Useful Post:

    Jamest5r (Tuesday 11th August 2015),stribo (Tuesday 11th August 2015)

  19. #17
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    You can bolt the manifold to heavy plate to help prevent it deforming while welding

  20. #18
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    Yea, I had to true mine up on a piece of sandpaper clamped to a sheet of glass, but it wasn't as bad as yours Rob, I'm surprised you couldn't see that warp before fitting it
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  21. #19
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    Quote Originally Posted by claymore View Post
    Yea, I had to true mine up on a piece of sandpaper clamped to a sheet of glass, but it wasn't as bad as yours Rob, I'm surprised you couldn't see that warp before fitting it
    To be honest I thought the cast manifold wouldn't have warpped.

    1996 850 T5 AWD - Self tuned M4.4 ECU with COP`s, B5254T ( S60R internals in a 850 block ) ostrich 2.0 , VXR injectors @ 3.8 bar, K24 turbo with a 6+6 compressor wheel, 3.25" MAF, top mounted Dump Valve, RN Exhaust manifold, 3" downpipe with 200 cell cat, 2.75" Stainless exhaust, Brembo calipers, S60R brake discs, stainless RIP kit, 3" Throttle body,

  22. #20
    Whiny Old Git
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    I know what you mean, but mine did as well
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