Piaggio Porter...labours!

Hi!
I own a Piaggio Porter idem Hijet van, from 2000, petrol-engine 1.3/16v 65 000km
I am the only private individual in my countryside (03380 France) to own this type of vehicle and of course there is no Piaggio or Daihatsu dealer in the region.
My truck stayed four months on props before I bought a rear axle and a transmission (from Italy) I had to replace.
No problem with cold engine start. The truck runs normally. But after a few kilometres and when the engine is warm, it begins to cough. The engine labours. The combustion seems imperfect. When stationed, the idle speed is not working properly, is irregular. But the engine doesn’t choke.
Here are the main inspections I did myself:
• I replaced the 4 spark plugs (last replacement last summer 2012) with the old ones – same symptoms.
• I replaced both ignition coils
• I tested the resistance of the connectors and bands of the coils and the spark plugs – same symptoms
• I disassembled and cleaned delicately the exhaust gas oxygen sensor – same symptoms
• I disassembled and cleaned diverse connectors and sensors – same symptoms
• I replaced the fuel filter – same symptoms

Do you have any clue about the malfunctioning? At the end of the exhaust pipe, when the engine is warm, it was measured that the combustion is incomplete and the engine pollutes a lot. How can I test the EFI system? When you listen with attention to the engine, it seems that the ignition cycles are not efficient.

Thanks

Does the engine warning light:-

A) work
b) come on when it starts to "choke"

http://www.daihatsuhijet.co.uk/hijet-diagnostic-engine-warning-light-flash-codes/

No warning light on the panel, never!
Thanks

Timing?

Sorry!
What is timing?!

huchman wrote:No warning light on the panel, never!
Thanks

Bet the dashboard bulb is blown or removed.

And my hunch on your fault is the oh so common "vehicle speed sensor" failure.

Does your speedo work?

no no no everything works

Where i can find the speed sensor?
Tomorrow i had to test it!!

So does your engine warning light come on when you turn on the ignition?

Yes, engine warning light come on when i turn on the ignition and it stops after seconds! All right on the panel!
The engine cough only after a long time when 70/80° come of!
The engine is normaly cooled, system coolant ok, i think also intek air temperature sensor is ok!

HighlyJetted wrote:Does the engine warning light:-

A) work
b) come on when it starts to "choke"

http://www.daihatsuhijet.co.uk/hijet-diagnostic-engine-warning-light-flash-codes/

Did you check the ECU for fault codes?

Hi!
Are there any risks if i check the ECU to find fault code even if on the panel ( except when i start) the warning light isn't on?

Yes, you risk finding out what is wrong with your van!

I think he means does it store error codes even if the eml isn't on

Yes !exactly!!
?

Yes it does store previous faults - until you disconnect the battery.

Hi!
And if the trouble came from the catalyst?
Once again, the symptoms occur when the van is hot after few kms!!!
What are the symptoms of a broken down catalyst?

Did you scan it for error codes?!!!!!!!!!

Not yet!
On the connector i have black/white and black/brown wires, not a brown/white!
But i think i could bridge them tomorrow!

Do you have an OBD2 port instead?

No OBD2 port! just the standard connector!
(idem the photo: http://www.daihatsuhijet.co.uk/hijet-diagnostic-engine-warning-light-flash-codes)

Hi !
I've just made the diagnostic test by connecting the black /white wire to the brown/black wire ; I received no flashcode but the engine warning light just goes on and off continually and rapidly.
Is the EFI broken down? Thx

That is a good sign as it means that no error codes have been reported.

So I would guess you have a fully mechanical problem.

I could be tempted to start with the fuel filter, fuel pump and pipe work.

Often they are totally rust filled, limiting fuel supply so they have no power.

Hi!
Fuel filter is new!
This morning i've put down the fuel tank and cleaned all pipe work and all evaporative fuel pipes! (purge, charcoal canister...)
The fuel pump is Ok!
No trouble, very clean, good condition!
I 've also inspected the 4 injectors and the fuel pression regulator! seems in good condition!!
I've take down catalytic 3 ways and exhaust! engine starded and hot, came the same symptoms: throttle labours!!! slowly!
but never the engine stop himself!
The symptoms came only when the engine is up in temperature!

The coolant temperature sensor is a 2 in 1 sensor, half does the gauge and half does the engine.

If it breaks down inside it will give false readings, but no engine warning light.

Maybe look at that sensor (on the back of the cylinder head at the gearbox face)

Test data I made is here:-

https://hijet.forumotion.com/t1794-test-your-suspected-faulty-sensors

Hi!
I've just tested the coolant temperature sensor. It gave me between pin 30 and 31 3.66 kohms (8°C outside). I think it's OK.
But now when I tested the 3rd pin with brass body, I have no figure or unstable figures. What do you think? Is it the half dash gauge sensor that does not work? Is there another way to check it? Can I find this part easily on the web? In England maybe? Because in France......
Thank you so much for your help )

The 1 pin to the brass body is the dash gauge sensor - does your gauge work?

yes, the gauge of the temperature engine on the dashboard is working
everything on the dashboard works properly since the beginning

Hi!
Have you got another idea?!!
Thank you so much for your help!