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Thread: Getting atrocious mileage?

  1. #51
    Join Date
    May 2018
    Location
    Albany, NY
    Posts
    143

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    Updates:

    Fuel sender gasket replaced and used the forum suggested sealant. Hylomar Blue Gasket Marker. Now I can fill the tank fully again and continue testing.

    Data: 15 mpg city for a brief city stint, and 14 mpg for a brief highway stint. Followed up by a 19mpg 130 mile highway stint.

    New development > Hard start up when warm unless I give it gas AND sticky throttle cable/ITB's hanging. Gets worse when warm. A blip of the throttle fixes the hang.

    Checked/lubed the cable seems alright. This weekend I'll partition cable vs ITB issue by separating them and see if rev's still hang. I know that pulling on the ITB controls still had revs hanging but I can't be certain that activating that control didn't pull the cable with it and the two were partitioned that way. Also I find some very minor vertical play in one of the butterflies. Two set screws are on tight.

    Here is what the idle sounds like





    Next courses of action:
    Take cable out and make sure there is no hanging/isolate it/check free play.
    Inspect hoses see if there is any air leaking past closed throttle causing hanging revs.
    Find out what IACV setup I have and whether I have TPS > check their operation.
    Look into the play in the butterfly and see if it's causing the issue and maybe hanging causing air to sneak past it.


    Side note: If you're ever concerned with lack of heat in the car, take out the 6 screws holding the pedal box cover plate on. Lack of heat will not be a concern anymore. Been driving around without it while troubleshooting and it gets HOT.

    Pending:
    New o2 has arrived and will be replaced.
    Adapter for fuel pressure gauge/tester is on the way.
    Last edited by Vovchandr; 06-10-2019 at 08:38 AM.
    2001 Caterham Superlight R

  2. #52
    Join Date
    May 2018
    Location
    Albany, NY
    Posts
    143

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    Here is the hard start up video when warm (you can hear fan turning on, I'm at operating temp.


    It does start if I give it the gas while starting > throws black cloud of gas of the exhaust.


    Also worth noting that my temperature has been abnormally low. I'm typically a little below 80, but have been close to 60 on the recent 130 mile highway stint.
    2001 Caterham Superlight R

  3. #53
    Join Date
    Jan 2006
    Location
    Seattle-ish
    Posts
    1,128

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    I can't remember if this was mentioned before; is it possible the TPS has rotated slightly on the mounting screws and is no longer calibrated correctly? If so that would cause the map to effectively shift and supply the wrong fuel and timing for a given throttle opening. If you have the software connecting to the Pectel, it should be easy to check.

    -John
    Westfield SEiW
    2.0L Duratec
    Throttle Steer

  4. #54
    Join Date
    Apr 2007
    Location
    Bozeman MT
    Posts
    493

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    I keep coming back to the coolant temp.....My money is on the coolant temp sensor or a thermostat being stuck open. It's overfueling 'thinking' that it's in warm up mode all the time.

    dave

  5. #55
    Join Date
    May 2018
    Location
    Albany, NY
    Posts
    143

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    Minor updates

    Got the fuel gauge installed on the rail. Reading right around 50psi idle and while revving. From brief research seems a tiny bit high/normal, especially if I'm mapped properly for it.






    Picture of the coolant temp, while at operating temp. I do have a lower temp thermostat put in, maybe I should switch it. Lower temp Tstat from my understanding should really effect much other than opening sooner but my operating temp should still be the same. It has been fluctuating overall. Normally it's right around 80, has crept up a little higher and this is now unusually low




    As far as the ECU, does anybody know why I get this message?

    ""DESC does not have enough information to use maps currently in this ecu. If you have a different set of maps on disk, you may be able to reprogram the ecu with them. Do you want to try that""
    "DESC could not find a compatible profile. To use this ECU/MAP you will need a profile for T2v1-15:TPS/MAP fuel TPS lgn"

    I do have a profile folder "T2 V1-15 NA" with "ADABAPAC.AAB" which I have deciphered should work for T2 and is NA profile.


    So far I believe my sticky throttle/hanging rev's are due to a 1 butterfly in the ITB's sticking. Testing pending.
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    Last edited by Vovchandr; 06-12-2019 at 11:36 AM.
    2001 Caterham Superlight R

  6. #56
    Join Date
    Jun 2013
    Location
    N. California
    Posts
    61

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    I had similar cool running issues with my Duratec powered Caterham. The cooling system was an octopus of hoses heading to a 1.5" tube with three 5/8" branches. After looking over some info provided on this forum

    (http://www.usa7s.net/vb/showthread.p...cooling+system)

    and revising the system the T-stat now works properly and the engine maintains a constant temperature of 80C. I also ditched a few pounds of hoses and tubing .

    If you are running cool enough to stay in the portion of the map that provides warm up enrichment you're going to get poor economy and not do the engine any good. Before you start replacing T-stats look at the routing of your cooling system. Maybe you have a similar issue?

    Andy

  7. #57
    Join Date
    Dec 2014
    Location
    Los Angeles
    Posts
    204

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    Unless you are using huge injectors, the Duratecs run at 42-43 psi.

  8. #58
    Join Date
    May 2018
    Location
    Albany, NY
    Posts
    143

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    Update:

    Replaced the o2 and here is the latest data.

    City low RPM cruising 12.7 miles .493 gallons. ~25mpg
    All highway ~70mph average in 6spd 30 miles 1.481 gallons ~ 21mpg

    Average ~21mpg

    I think I'm in the right ballpark now?
    2001 Caterham Superlight R

  9. #59
    Join Date
    Feb 2009
    Location
    NYC
    Posts
    4,271

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    That sounds better!
    Mike
    2010 Caterham CSR with Cosworth 2.3 Duratec
    2018 Caterham 420R with 2L Duratec 210hp at Donington UK
    1975 BMW CSL Group 4 (restoration - engine and dry sump install time)
    1977 Holden Torana "A9X" (awaiting restoration)
    1985 Holden Commodore Group A (restoration - engine rebuild)
    1982 Ferrari 400i (will repaint to original color in 2020)
    1965 Ford Mustang Fastback "Holman Moody"
    1992 Ford Escort RS Cosworth WRC (fettling after long period of storage)
    1990 Range Rover 2 door Classic

  10. #60
    Join Date
    Jan 2018
    Location
    California
    Posts
    18

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    Quote Originally Posted by Vovchandr View Post
    Updates:


    New development > Hard start up when warm unless I give it gas AND sticky throttle cable/ITB's hanging. Gets worse when warm. A blip of the throttle fixes the hang.

    Checked/lubed the cable seems alright. This weekend I'll partition cable vs ITB issue by separating them and see if rev's still hang. I know that pulling on the ITB controls still had revs hanging but I can't be certain that activating that control didn't pull the cable with it and the two were partitioned that way. Also I find some very minor vertical play in one of the butterflies. Two set screws are on tight.
    I've got this issue too, I did some Googling about those TWM throttles (what I've got on my Zetec), and found Honda guys complaining about the same issue. One guy fabbed up a secondary return spring to get them to snap all the way closed. Have been planning to look into doing that myself, after fixing other things...

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