Engine Hesitation During Long Journeys

[Technik21 0]

Hi Guys

 

The engine on my 1.9 GTI (1993 - CAT) starts to hesitate\misfire when it gets hot. This only seems to happen after about 2 hours of continuous drivng.

If I let it cool down for say 30mins. Then we are back in action, but only briefly as it again starts to hesitate.

If I'm driving around town, or on a short (1hr or so journey), then all is well.

So general everday driving is not a problem.

 

I have recently changed the plugs, but need to investigate further.

Does this ring any bells, or can you suggest likely areas that would cause this.

I'm guessing HT leads, Coil, Dis-cap, rotor, Ignition module or even the fuel pump.

Where to start though?? If it takes a 2 hour journey to check each component, I could be a while!

 

Any advice or pointers would be appreciated.

 

Thanks

[cybernck 403 1 Cars]

I've had this on all my CAT GTI's.

 

Distributor cap & rotor, coil, ignition module - check them in this order .

[kkronja 0]

What is the proper Ignition module for '91. CAT 1.9 GTI ?

 

On mine I have found a Bosch 0227100111 (grey with 6pins) that is under suspicion of occasional misfire, but I have read somewher that the original is the 0227100123, blue with 7 pins- the cable that is plugged in has 6pins-what is the 7th pin for?

I have tried a Transpo brand module BM302 (7pins) that is supposedly replacement for 0227100123, the car starts but it splutters from the start when I give throttle-no good then, eh- I have found a genuine Bosch 0227100123 on ebay, but I don't know what to expect from it-maybe some more spluttering?

 

Thanks!

 

Ivan B.

[kkronja 0]

...I have another couple of questions:

 

can the ignition module be tried on a car for a minute or two without mounting it on heatsink plate(just plugging in the cable)-I guess it wont get hot enough to harm it, but I dont know if the heatsink acts also as an earth connection or something...

 

Also I had a quick check under the dizzy cap, and after mounting it back I noticed that the cap(which is not original Ducellier but Commercial Ignition XD197 replacement) has a small tooth that prevents it to sit completely flush with the distributor body(I guess it is designed for a dizzy with a matching slot, but mine doesnt have one)-after tightening the bolts the cap is a bit tilted -it does function, but I guess the contacts arent on the same distance for all the cylinders(please see the picture).

 

Does anyone have any experience with this. Should I grind down the tooth, so it can sit flush with the dizzy body?

[welshpug 1,666]

have you rotated the cap to see if it fits properly maybe at 180 degrees?

[kkronja 0]

...no slot on either side of dizzy body-the HT cables should go downward from the dizzy cap, right??? At least, this was how the previous owner has fitted it.

[welshpug 1,666]

if the cap did fit the other way then its possible that the body of the distributor is bolted on 180 degrees out.

 

however if the cap simply does not fit then its the wrong one and i would get the right one.

[kkronja 0]

...it's a good point, but I guess if the camshaft (and its slot for dizzy rotor) is at its proper location, and the distributor and the cap is not ,it should have problems giving spark to wrong cylinders, but the car functions normally.

 

All the info I have found about 19GTI CAT with Motronic and Ducellier ignition state that i have the right XD197 replacement cap- if someone knows better I'd be very grateful for info.