Alright. I need some help with this one.
To catch up:
Last I wrote, I was expecting my cut out issue to be an ignition problem. I chased this around for a couple weeks. Replaced the plugs, tried a couple gap sizes. Replaced the cap and rotor with new nissan parts.
Changed plug wires. Rechecked timing. No change.
I then noticed my ignition coil was getting hot after long drives and was going to relocate that next.
I also noticed that turning the car off for a few seconds and back on would stop the problem for a while. This made me think maybe something electrical was overheating or maybe even a bad ECU.
But then I noticed another very repeatable symptom that changed my line of thought. Every time I filled up the problem would go away completely until I got down between 3/4 and 1/2 tank, then it would come right back.
Uh-oh fuel issue after all. Right about this time a started noticing some smoke on shifts.
Finally hooked up a fuel gauge to watch as I drove around and sure enough the fuel pressure would plummet as the motor cut out. Yikes!
Fearing a lean condition I drove the car gently until the tank was below half tank so that it was in it's problematic state, then parked the car for investigation.
The smoke was getting worse so I started with a compression test.
Wet test, no improvement damn.
Fearing the worst,
I got out the borescope.
predetontion marks on all cylinders.#2
piston looks melted, hence the low compression.#4
rust pitting on the wall (I assume from sitting for 15 years)
Obviously, that sucks. I'll have to do a tear down now.
However, before I do that I would like to sort out the original issue that got me here first. That way after rebuild I'm not right back here with a fresh motor to cook.
I also noticed the fuel pump would be much louder after a long drive.
I changed the fuel filter, and did the larger fuel pump power wire upgrade to bring my voltage from 12.5V to 13.9V No change, still had pressure drop.
All I could think is that something went wrong with my Walbro pump updgrade.
I opened the tank in hopes of a smoking gu.
There was some crud on the filter sock and some crud in the bottom of the tank but it just doesn't seem like enough to actually clog the pick up.
What do you guys think? Has anyone seen this before?
I can't seem to find anything in by searching.
I used a Sentra install kit for the Walbro because I couldn't find any pulsar specific stuff. My stock pickup was broken. Maybe this one isn't getting to the bottom of the tank? I could believe that if it starved at an almost empty tank but 3/4 tank?
Are there new pick-ups available?
Besides the fuel issue, rebuild questions.
I don't plan on pushing the motor past where it currently is. Running 1 bar boost. I just want a fun commuter car, my 510 is my performance/project car.
I have VET pistons and new Nissan rings.
I plan on rod bearings while I'm in there are there lower cost brands that are as good as OEM?
Same question for gaskets I suppose. I can get a Nissan head kit for $250, is there a better option for that price range?
I guess this gives me an opportunity to re-shim the head and grind the valves... trying to look on the bright side.
Also, while I have the head off and can access the back of the motor easy, are there other things besides all the dry rotted hoses that should be replaced while access is easy?
Thanks for any input.