Really really really not happy

[Slugsie]

OK, after finishing off fitting my new cylinder head on Monday, and taking yesterday off for a break, I took my Surf out for a shake-down spin today to see if everything was OK.

Well, it wasn't, and not by a long shot.

First thing that became very apparent was that it has virtually no power. Pulling off was even slower than usual, and accelerating at speed was abysmal. Once I got on the motorway, I had to really push it to get above 60mph. Then, on the way back.... it overheated!

So, got recovered from the motorway (thanks Britannia, got to me in around 20 minutes, I can honestly say that they are a superb breakdown service), and Surf is back sat on my driveway in disgrace.

I'm really hoping that the overheat is due to an air-lock and a flush/refill (which I planned to do after running a week or so anyway) will solve that problem. However, the lack of power is another thing. As I have mentioned in another thread, it started to be very lumpy at idle a few weeks back (before the head swap), so I don't think the head is (directly) related. The injectors were very black and sooty, so I'm suspecting one of them is knackered. Is there any way that I can test them myself, or should it be done by a pro? I'm pretty sure that the timing is right, but that's something I'll check when I have a couple of hours to spare.

I really don't want to spend too much more fixing this car, as I am planning on selling it anyway (to get a 3ltr), and the head swap was to help make it more saleable.

Can anyone help, and give me some advice?

[BUSHWHACKER]

Sounds like you've got no turbo boost. The engine will idle o.k. but when it's asked to move two tons of truck it's absolutely gutless.
Is the green light coming on? can you hear the turbo whistling? there's a short rubber pipe with a 90 degree bend on the side of the throttle housing, near the throttle position sensor, make sure that it's connected, as it's quite easy to knock off.
Have you tried checking for fault codes or resetting the ECU?

[Slugsie]

Sounds like you've got no turbo boost. The engine will idle o.k. but when it's asked to move two tons of truck it's absolutely gutless.
Is the green light coming on? can you hear the turbo whistling? there's a short rubber pipe with a 90 degree bend on the side of the throttle housing, near the throttle position sensor, make sure that it's connected, as it's quite easy to knock off.
Have you tried checking for fault codes or resetting the ECU?

As best I can tell, the turbo is working fine. I can hear it spinning up, and the turbo light does illuminate. The way it's acting, my suspicion is that there is a mis-fire on one cylinder, probably caused by a blocked injector. Anyone know how I can test injectors myself with having to send them off?

I haven't checked for fault codes today, but I did check yesterday after the engine had been fired up for the first time and left to idle for 5 minutes, and quickly run round the block. No codes reported. The ECU has been reset (the batteries were disconnected for 4 days during the head swap).

[Danno]

I had a similar problem on my 89 manual. The turbo span up ok, the green light illuminated but very low on power.

I took it to a turbo specialist and they diagnosed about 0.5 psi boost. I stripped the turbo to find a crack in the exhaust side of the turbo housing running from the wastegate to the exhaust port. Thus causing no boost.

Replaced it with a spare out of the shed and bingo..........rocket surf, well as fast as a 2.4 goes anyway.

[227angrydonkeys]

coming for m the fast jap car world, does anyone ever bolt bigger turbos onto these and with a diesel does it make any difference?

[MattF]

If I remember correctly, there is one beefier turbo which is practically a
drop in replacement for the existing one. If I can ever remember where
I saw the info, I'll post the link.

[foggy]

Remember that this came up before,check your valve clearances(tappets)

[BUSHWHACKER]

coming for m the fast jap car world, does anyone ever bolt bigger turbos onto these and with a diesel does it make any difference?

Bigger turbo means more turbo lag on a Surf!

[BUSHWHACKER]

If I remember correctly, there is one beefier turbo which is practically a
drop in replacement for the existing one. If I can ever remember where
I saw the info, I'll post the link.

Did someone say link?