T25 1.9 W/C Running problems

[cartspj]

I know similar posts have been put on here but on reviewing them I can see no solution that seems to have worked. Our sad tale starts last year when my 1.9 watercooled T25 developed a problem with stalling at junctions, stuttering/kangarooing on acceleration and lack of power. It happened 2 journeys in a row and was too unreliable to drive. I decided to park it up for the winter and deal with it this spring.
When I re- taxed it and started it up this spring the issue seemed to have gone away........drove it around a couple of times before I had to get the engine replace (separate issue – I think).
I bought a recon from Elite and got a garage near where I broke down to fit it. After fitting they struggled to get it to tick over when cold (alright when hot – if anything was racing) they stripped down and cleaned the carb but this seemed to have little if any effect.
Any way I pick the vehicle up as I had trips planned and lived with it for a few weeks and put the 500miles running in on it. During this time the van had little power, smelt of fuel and drunk fuel for a pastime. One thing I also noticed is that there was a big ‘step’ between 2 and 3rd gear. I then took it to my local (very good) garage for 500mile oil change etc. They did the oil change etc and looked at the carb set up and decided it was running too weak. Reset this and I took it away, still had some issues with tick over but better.
Last weekend I did a trip to Cornwall (140miles), all the way down it was sluggish and over the weekend it wasn’t running great but nothing too bad. On the return journey it all started happening. It re- developed the problem with stalling at junctions (wouldn’t tick over at all), stuttering/kangarooing on acceleration and lack of power, and at one point backfiring when I dropped from 4th to 3rd. On the motorway I couldn’t get over 60 mph. After about 100 miles I came off of the M5 and stalled at a junction restarted the engine and it then ran perfectly for the last 40miles......better than it ever has. Next morning I decided to get it back to the garage, it started OK, tiched over ok and drove for about 15mile perectly again until I turned off of the main road and as I changed down from 4th to 3rd it backfired twice before losing power and stuttering etc again. Limped it to the garage and left it there.
The way I see it is that both the old and new engine had same issue so it’s not an engine fault. The other most obvious causes are fuel blockage, carb and choke. All of which the garage is checking out however despite being a good garage they are not T25 experts so any pointers / advice would be gratefully received as I am due off on our summer hols in the van on Saturday assuming we can mend it.

[Ian Hulley]

Crap petrol
Crap IN petrol
Watery crap in petrol
Blocked fuel filter
Blocked carb fuel inlet filter
Decaying fuel lines

Have you replaced plugs,leads,cap,arm, etc ?

Ian.

[CovKid]

If you've had a recon, I can only assume that the same ancilleries were transplanted across. On that basis the above items (one or more) is no doubt the problem and substitution with a known 'good un' to rule out each in turn would be the best route if the cause can't be found.

You don't say where you are as I or another 80/90 owner would be more than happy to help you trace your problem I'm sure.

[kevtherev]

I'll go with water in the tank
run some fuel into a jar and see if anything separates out...

have you looked at the fuel filter?
change it ..they're oly a quid

checked the carb filter?
clean that too

by pulling off the inlet pipe to the carb while the engine is running
you should get good hearty squirts of fuel from the pump, if not then the pump is shagged
could be another cause of your trouble.

I would be looking also at air leaks, from the vacuum hoses and the braided pipe that runs from the manifold to the bulk head (brake servo)

do one thing at a time..

[Ian Hulley]

Can't believe that a proper garage wouldn't have changed the fuel lines and filter though ? The little filter in the carb fuel in line they should have found when they allegedly stripped the carb.

I'd be replacing the lot, fuel hoses from the tank outlet to a new inline filter, hose from filter to the plastic tube, plastic tube to the pump, pump to the carb, carb to the return plastic pipe and the last hose from that to the tank return inlet. Refill with new clean fuel and see what happens then. It could be the tank's shot and a large piece of crap's finding it's way to the outlet ?

Has the pump been tested as OK ?

Ian

[Ian Hulley]

by pulling off the inlet pipe to the carb while the engine is running
you should get good hearty squirts of fuel from the pump, if not then the pump is shagged
could be another cause of your trouble.

Kev meant to say not anywhere near anything hot what-so-ever or else your problems will be well and truly over anyway !

[kevtherev]

er yes..

into a jar with the lid on and a hole in the lid for t'pipe

[CovKid]

If it stinks of, and is drinking petrol, it doesn't suggest blockages to me - tho you could have a leak somewhere ofcourse. Sounds like air getting in and perhaps an ignition problem thrown in to further make it difficult to pinpoint. This is all shot-in-the-dark diagnosis from all of us. Without the engine in front of you its impossible to check, test and diagnose anything, pretty much like working blindfold. If you can find a buddy with a runner who would be willing to temporarily swap a few items, you may save a lot of time in the end but however its tackled, this is going to be an AA style approach, ruling out nothing but checking systematically.

[cartspj]

Thanks for the advice.......garage is currently looking for a new gasket for carb as when they removed the carb they found it had been installed with some sort of sealant ( Ididn't catch the name), the mechanic says its the last thing that they sould have put on the gasket because it was being 'disolved by the petrol and taking crude into the carb. This may explain the latest issue but not the previous problems s he'll carry on looking. I intend to print off the advice from here and pass it on so many thanks and keep it coming.

[docklad]

just got back from a week in the welsh hills. Friend of ours had very similar issues on drive down. I changed the in-line fuel filter which was donkey's years old and wrecked inside. Cleaned all the plugs thoroughly put a few more juberliee clips here and there and recieved a call from them when they got home to say she went like a dream for the eighty mile journey. You never know it could be simple.

[cartspj]

Update - carb all cleaned up, according to garage start fine from cold this am, as soon as it heated up started running rough etc . Still looking for fault, but tried all suggestions/obvious one. As a result cancelled first 1/2 of hols......doh!

[kevtherev]

so did the auto choke open ok?

[CovKid]

Well, on choke the mixture is rich which may well mask a weak mixture or dodgy ignition system. My money is on an air leak, either below the carb (bottom gasket), a leak on the carb itself (throttle flap wear or some other route for air), brake servo pipe (and possibly associated valve), a mixture screw thats been set optimistically, a loose or damaged vacuum hose and last but not least - a clogged up air filter. Certainly worth seeing if it runs better with air filter removed.

If its not one of those then it might be ignition or mechanical issue, but as I say, my money is on a weak mixture. The fact it runs on choke but gives up the ghost when choke comes off would point in that direction.

[cartspj]

Yes auto choke did open fine, will pass other suggestions on. thanks

[kevtherev]

brake servo hose.. fill it with water see if it leaks