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mitch1204
Novice
May 31, 2014, 9:24 AM
Post #1 of 10
(4341 views)
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91 Capri Won't Idle
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Hi, I bought a 91 Mercury Capri, 1.6L with 90K miles on it. It ran perfect when I bought it. Since the car done some sitting I wanted to go through the engine.
It all started when I put a new timing belt set and water pump on it. It wouldn't start. I tore it back down and double checked my timing and all the gears were correct.
I finally pulled the fuel filter off and nothing but brown sludge poured out of it. I dropped the tank and sure enough it was rusted out bad. So I bought a new tank, new fuel pump and screen and a new fuel filter.
Now it will start but will quickly die. If you rev it up above say 2000 rpms it runs smooth as a kitten. Try to idle and it stalls. Okay now I'm thinking injectors so I buy a kit and clean them replacing the screens and o-rings. All spray a good fine mist. I also replaced the intake and throttle body gasket.
It still hasn't made a difference. It still won't idle.
One thing I notice now is when I pull the fuel line off the filter there is no pressure. I've changed the fuel pressure regulator, no difference. It's pumping or it wouldn't run. This car doesn't pressurize with the key on. Only in start and run does the fuel pump come on.
Either I stretched something when I jacked the front of the motor up or something when I changed the tank. A couple things about the tank. I noticed it wet around the filler hose so I know I need to tighten it.
Also mounted to the old tank was a rollover vent. The new tank didn't have that bolt hole so I left it hanging. Is it possibly laying on it's side venting the tank and causing me problems?
I double checked my vacuum lines as that was my first thought. To me it acts like it's starving for fuel but I have no way to check the pressure the way that thing is set up. You need an inline tester. But the rail should hold pressure and it's not.
New parts: Complete new fuel system, complete new cooling system as it had a cheap plastic radiator and the fan switch was bad so I went through that. New cap, rotor and plugs. New PCV, timing belt set and front belts.
Any help would be appreciated. It's thrown me for a loop.
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mitch1204
Novice
Jun 1, 2014, 4:56 AM
Post #2 of 10
(4302 views)
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Re: 91 Capri Won't Idle
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No ideas? :(
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Discretesignals
Ultimate Carjunky
/ Moderator
Jun 1, 2014, 9:40 AM
Post #3 of 10
(4294 views)
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Re: 91 Capri Won't Idle
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Kind of odd that a fuel pressure issue would cause it to run fine above 2K, but not idle. You would have to T in a fuel pressure gauge and then monitor not only fuel pressure, but fuel pressure bleed off rate. If you have excessive bleed off you'll need to figure out if it is something to do with the regulator, leaking fuel injector(s), faulty check valve, or a problem in the fuel tank with the supply line coming off the pump.
You should check for major vacuum leaks and make sure that the idle speed control system is functional. The ISC has two parts a solenoid that is computer controlled and a wax thermal valve that is closed as coolant temperature rises.
Another thing that could cause it to stall out at idle or have a rough idle is a stuck open EGR valve. The EGR valve shouldn't be getting vacuum at idle speed either.
Since we volunteer our time and knowledge, we ask for you to please follow up when a problem is resolved.
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mitch1204
Novice
Jun 1, 2014, 3:58 PM
Post #4 of 10
(4283 views)
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Re: 91 Capri Won't Idle
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Thanks discretesignals. I doubled checked the vacuum today and all is good. I'll focus on the EGR tomorrow.
I know the injectors are not leaking and I've had two fuel pressure regulators on it. I went over the gas tank today so that's eliminated. The only thing I can think of is maybe the check valve in the fuel pump but that shouldn't make a difference when running. But then again I only can check for residual pressure with it off. Maybe I got a bad pump/check valve? I have a second new one I might swap tomorrow.
I did run a compression check today and all are around 140. I ohmed all the plug wires and they are good. I do hear a little miss but that can be the timing. I need it idling to set the timing correctly.
When I try to hold the throttle steady lets say 2000 rpms it does raise and drop on occasion. I figured that's the computer correcting. Another thing when I hold it at 800 rpm with the pedal then give it gas sometimes it doesn't respond. That got me looking at the TPS and VAF but it tested okay.
I'm like you with the pressure drop so I'll go over the pump tomorrow. It might be that $20 ebay special, lol.
I cleaned the ISC but that doesn't test it. I have a spare one of them so I'll swap it out.
I found out that car uses the Rotunda Super Star II tester. I need one of them and an inline fuel pressure tester. I wonder if they make an inline shrader valve for the rubber fuel line? I'll use my other tester. lol When I jumped the fuel pump test connector she pumped great.
Would you think maybe the pickup, igniter, ignition module or ECU cause them problems?
(This post was edited by mitch1204 on Jun 1, 2014, 3:59 PM)
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mitch1204
Novice
Jun 1, 2014, 7:59 PM
Post #5 of 10
(4278 views)
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Re: 91 Capri Won't Idle
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Another thing I forgot discreet is I noticed my cooling fan is not coming on like it should. I already replaced the fan switch and relay. I have noticed it running while the car is running.
But a few times the gauge is above 3/4 and I feel it should be running after I shut her off. I turn my key off halfway between run and off the fan will come on. Not off or not on but in between the two. I have to play with the key a little.
That kind of sounds like I'm having ignition switch problems too.
Can that be related?
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mitch1204
Novice
Jun 2, 2014, 3:26 AM
Post #6 of 10
(4272 views)
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Re: 91 Capri Won't Idle
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This car does't have an EGR system only an EVAP. I guess because it's made in Australia? I wonder how it was sold in the USA. That's strange.
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mitch1204
Novice
Jun 2, 2014, 6:33 AM
Post #7 of 10
(4269 views)
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Re: 91 Capri Won't Idle
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Woot Woot! I fixed it! That was a tough one to figure out.
I said this morning let my triple check my timing. I pulled the cover off and lined up TDC and everything looked good. Then when I went to put the cover back on I noticed a deep grove cut in it from the exhaust gear. I pulled the valve cover off to make sure the cam was okay and it was. Then I tried to tighten the exhaust gear bolt and the gear was trying to go crooked on me??? So I broke her down and took the gear off.
Sure enough the tit on the cam wasn't sitting in the hole on the gear. It shifted about 3/16" to the side making my exhaust timing a little over one tooth off. I couldn't see it before for the big washer covering it.
I torqued it down properly and went over the intake cam and it was loose too but not as bad to shift off the tit. Evidently the last person that worked on the head didn't tighten these bolts down correctly. Then I put a new timing set on it and I guess the extra tightness of the new tensioner was enough to make it jump.
Now to buy a new top and some new struts and I should have a pretty fun toy!
Thanks for listening to me blab and scratch my head! 
(This post was edited by mitch1204 on Jun 2, 2014, 6:35 AM)
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Hammer Time
Ultimate Carjunky
/ Moderator
Jun 2, 2014, 9:23 AM
Post #8 of 10
(4262 views)
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Re: 91 Capri Won't Idle
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So, what you are saying is that you bolted the timing gear on and totally missed the dowel pin?
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We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.
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mitch1204
Novice
Jun 2, 2014, 12:52 PM
Post #9 of 10
(4260 views)
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Re: 91 Capri Won't Idle
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I just bought the car. The cam gears were loose from before I bought it. It also has been sitting.
I put the new timing set on and didn't notice the exhaust gear sticking out 1/8th inch at that time. This time I caught it and first pulled the valve cover. After seeing that was okay I attempt to tighten it and noticed it going crooked. So I stopped and took it apart to see what was happening.
No, I'm not stupid enough to miss a dowel pin if that is what you are saying. I had no reason to take the cam gears off to put a timing belt on.
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Discretesignals
Ultimate Carjunky
/ Moderator
Jun 3, 2014, 12:43 AM
Post #10 of 10
(4248 views)
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Re: 91 Capri Won't Idle
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Glad to read you got it running good again. Thanks for the follow up. Can be reopened upon request by the OP.
Since we volunteer our time and knowledge, we ask for you to please follow up when a problem is resolved.
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