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FrankenJeep
01-14-2003, 08:26 AM
Well I thought I could wait a week or two before getting serious about fixing this, but the Chero thought otherwise.

I'm having a problem where the engine is shutting off with no warning. Its like a switch, one second its running the next it quits. It only does it when the engine is warm; not cold; not hot. Most often, its right after I stop at the store for a minute and start right back up. But it's also done it on the highway, and cuising around town.

Most times, I can restart it before it comes to a complete stop. However, this morning it wouldn't start after after dropping the kids off at the sitter's. Once I got it started, it cut off less than 2 blocks later and wouldn't restart. Wait 5 minutes, restart, run for 2 more blocks. After three cut-offs (with no immediate restart), I finally got it to the house and traded it for my other ride.

Here's what I know.

- Happened the first time a month ago. The engine wouldn't restart so I thought I was out of gas (showed 1/8 tank). Happened on the highway at a steady-state 60 mph. Air temp was in the 20's. A friend came by with gas after an hour, and I didn't have any more problems that day.

- During the next few days, it continued cutting out so I thought it might be a clogged fuel filter. Replaced the filter with no improvement.

- When it happened, it would usually do it more than once. Each time I could hit the starter and it would retart immediately. Again, when the engine comes up to full runnning temp, it goes away.

- This morning, it wouldn't start after sitting for 10 minutes at the sitter's. That hadn't happened since the first incident (always occurred after the engine had been running). The choke appeared to be okay. I was getting gas. I could spray in some starter fluid and get it to stumble which leads me to think its fuel related. The second to last time it quit this morning, I was sitting in a parking lot letting it idle. No cough or sputter, it just stopped running. The last incident was on the highway on the way home.

- Seem to take at least 10 minutes from a cold start for the problems to start. It doesn't always happen, and it doesn't appear to be too related to air temperature.

- I've been reading some threads on EGR problems. Does this fit the symptoms? A shade tree buddy of mine suggested that I could pull the EGR and hit it with some silicone to free it up. Is there a good way to isolate the EGR to verify if its the problem?

- Would water in the fuel system do this? It may be a coincidence, but it seems to get worse the lower the tank is. I always thought that water in the system would give me some sputtering.

- Vapor lock? I checked all of my lines and everything seems to be away from heat sources. Air temp this morning this morning was 23 deg F, and the temp gauge was barely in the 'green'. I would assume that vapor lock would be worse at full operating temperature.

- Carb rebuild? I have the Motorcraft 2 bbl, and it does have the typical problem with the accelerator pump. That's usually a stumble right as I hit the gas (when cold). The cut-off problem occurs even when my foot isn't on the gas. I was hoping to put fixing this off and upgrade to a 4 bbl. However, $$$ is tight so it might have to be a rebuild.

- Choke? Everything looked okay on a visual this morning. I think this carb has some of the emissions crap on it linked to the choke, and I think the PO disconnected (or broke) the wires from the temperature sending unit. However, I've been driving this for awhile without problems.

I'm a little stumped here. NAPA online shows new EGR valves at $100+, so I'm hesitant to spend $$ on the little sucker until I know that's my problem.

As always, any help you can give is appreciated.

andy d
01-14-2003, 09:04 AM
could it be the ignition module or the p/u coil? usually its an ignition trouble when it cuts out w/o sputtering. may be as simple as a bad connection around the coil or something.

WhompBigJeep
01-14-2003, 09:18 AM
That's exactly what I would say Andy. I had an 85' Jetta (never again!) and the p/u coil did the same thing. Freaked me out. It would just shut off. At first it would start right up again, a couple weeks later it took a few minutes, finally it took 3-4 hours. NO rhyme or reason to it. PITA. Good luck.

myndcrym
01-14-2003, 09:21 AM
Thats what happened to me a month or two ago. Change the ignition module. Fixed mine right up! Its cheap to like 15 bucks at auto zone!

Rich 89 Gr. Wag
01-14-2003, 09:29 AM
Ditto on the ignition module. Happened to me in my 87GW before replacing it. But, the ICM was $100 at the dealer. Can you really get the ICM (the one on the drivers side fender) for only $15 at Autozone??? I'll be ****ed!

mdill
01-14-2003, 09:55 AM
The newer Wagons used the module with the weather pack terminals,
same module as the old one, as far as I can tell but buying a Ford module
with GM connectors for a Chrysler product costs alot more :(

Mike D.

myndcrym
01-14-2003, 10:33 AM
Originally posted by Rich 89 Gr. Wag:
Ditto on the ignition module. Happened to me in my 87GW before replacing it. But, the ICM was $100 at the dealer. Can you really get the ICM (the one on the drivers side fender) for only $15 at Autozone??? I'll be ****ed!Yep! Thats it!!! Sorry man!!

BIGYELLOW78J10
01-14-2003, 11:28 AM
$40 at napa, $15 at Advance, autozone, $5 at the junkyard, $0 off my truck if I don't find you when you steal it!

Daniel

If I heard those symptoms on a new car I would say fuel pump relay, but thank god we don't have those!

FrankenJeep
01-14-2003, 12:04 PM
Thanks for the tips. I found the module info in the TSM, but it didn't mention one important issue ... where is the module located? redface.gif

Unfortunately, my next garage day just got moved into next week. So it looks like I'll be cruizin' in the Turbo Hyundai!?! for the next few days. There's barely enough room to carry my dignity in that thing. tongue.gif

myndcrym
01-14-2003, 12:12 PM
Drivers side fender under the hood! Box about 5in X 6in. Easy!!

BTW: its only gonna take 10 min. to replace

[ January 14, 2003, 07:13 PM: Message edited by: myndcrym ]

Bombadier
01-14-2003, 01:03 PM
my Chero's ignition module is on the pass. side by the starter solenoid. so far though mine's the only FSJ that i've seen that has the module located there. (haven't looked at any other '77s)

FrankenJeep
01-14-2003, 01:07 PM
Originally posted by myndcrym:
BTW: its only gonna take 10 min. to replaceThanks!!! That translates to only 30 minutes in my time. (My rule personal of thumb ... however long the manual says it takes; multply by 3) :D

The Preacher
01-14-2003, 01:13 PM
If you have a prestolite distributer they cost like $50 new. That would almost pay for a new distributor and module of the other kind, (don't remember what they are called). Then you could do a tfi upgrade too.

mdill
01-15-2003, 02:48 AM
76 - 77 had the prestolight, 78+ -> end motocraft, 78->87(?) used the
cheap ford module, 88(?) used the ford module with different connectors ($$).
I don't see any reason not to buy the early model box and swap connectors,
for 88+, all that is needed is some weather pack terminals/seals and the
crimp tool. (the crimp tool is kinda spendy though), but very usefull for future
wire mods.

Mike D.

FrankenJeep
01-15-2003, 01:29 PM
Thanks all. For the record it took me about 15 minutes including jacking the frame slightly for better access to the bolts.

Idled FrankJeep for 30+ minutes with no cut-out. I'll run it to work in the morning to verify that its fixed. The weatherman is calling for a good snow on Friday, and I wanna play!

TFI upgrade is on the list. I think its a little higher on list after this week's headache.

Cheers.

regrow
01-16-2003, 08:15 AM
I was having the same problems and it ended up being the pick-up coil after I replaced the ignition module and the ignition switch. You can test the pick up coil pretty easy. (if it's bad) It will resist 400 - 800 ohms between the purple and orange wires coming from the distributor and then after it shuts off it won't read anything. No resistance. The part is about 15 dollars and it's pretty easy to replace.