Going to be a repeat post from ELANSCAN forum, but I think I am giving up on trying to get a scan because that doesn't seem to be working. Going to try to tackle some of these troubleshooting/repairs one by one on my own -- and would like input on best order to attack these. Let me know if you have better advice as this will be the first time I am doing any repairs myself (fed up with mechanics in US who have never seen an M100 and don't follow my instructions).
*If you want to read background on the car, scroll down below. Bottom line right now is I have CEL 41/42 and definitely not running 100%, very inconsistent (runs well for a little bit, but stalls out every once in a while, exhaust pops every once in awhile, etc.).
1) Check earthing on all wires that do not require removing other parts
Question: Which wires can I check very easily, and what exactly should I be "checking for" on earthing connections? Sorry, I am a novice.
2) Ensure gap on magnetic pick up on CAS (not the HES) has gap of 0.008" - have read that could cure my problems
3) Reset timing (no telling if the mechanic set it correctly last time which was over a year ago)
If that doesn't work...
4) Replace HES - have one in reserve (even though car has less than 1k miles since last one was replaced)
4a) Does the single rotary vane need to be EXACTLY midway between the jaws or just pass smoothly with no contact? How can you ensure this gap is exact?
5) Reset timing again to ensure it is correct post-HES replacement
If that doesn't work...
6) Clean leads at connection to coil packs (pretty sure this will require me moving the coolant tank and large intake pipe)
6a) Make sure routing of ignition wires is not too close to the EST circuit wiring (read that this solved someone's problem)
7) Check earthing on coil pack
If that doesn't work...
Replace Ignition Control module (purchased new one from LEC member this week)
9) Replace coil packs
10) Replace ignition wires
If that doesn't work...
11) Replace Sparkplugs
Question: Will I need to check timing again after steps 7, 10, or 11?
Thanks in advance!
BACKGROUND
91 Fed, about 44k miles on it now
July 2010 (when it had about 37k miles),
Experienced some mis-firing (no CEL)
-Replaced Ignition Wires (Kingsborne)
-Coil Packs (standard MSD recommended here)
-Spark Plugs (NGK Iridium)
Things OK until...
August 2010, experienced some overheating while driving (fans did not engage)
-Replaced Thermostat (the existing one was definitely stuck according to boiling water test)
Things OK until...
November 2011
Experienced mis-firing again (CEL 41) - this time very badly, sounded like a helicopter driving and not all cylinders firing
Also noticed some loose metal chunks in my muffler (disintegrated cat?)
-Purchased Head Gasket Leak Kit -- no signs of HGF
Car basically sat in garage until...
December 2012
Car towed to mechanic for a flurry of repairs and upgrades:
-HES replaced (new version)
-New timing belt
-02 sensor
-Oil Cooler replaced/Oil Pan Gasket/Valve Cover Gasket
-Piper stainless 2.25" w/sports cat
-Piper ceramic downpipe
-Wastegate ported to 20mm
-ProTech suspension (w/SJS springs)
-Front upper ball joints/Front lower ball joints/Front lower control arms/Various bushings
-Rotors/Brakepads/Stainless hoses/Master Cylinder/Caliper Seal & Sliding Kit
Car runs like a champ for first time in a while, except getting boost creep when pushed hard until...
July 2013
Less than 1k since the above work, CEL Code 41 and 42 (can HES go bad that quickly!?) and car very jumpy
Garaged for another a year (frustrated after spending $6k USD+ in the car) until...
September 2014
Mechanic doesn't really worry about CAS/HES (CEL 41) or EST (Code 42)
-Fuel filter replaced
-Thermostat replaced
-Temp Sensor replaced
Car runs much better than it did when I drove it to the mechanic (very jumpy, stalling out), but still have CEL 41/42 and definitely not running 100%, very inconsistent (runs well for a little bit, but stalls out every once in a while, exhaust pops every once in awhile, etc.)