hey all, it's been awhile since I posted but I got a few questions about the fuel injection system.  you guys seem to be the most knowledgeable here on the subject   

I have an EFI 1.6 8V that seems to run rough kinda intermittently. from time to tome it bucks on takeoff while accelerating and just lacks power overall. it stalls when deccelerating to stop signs and lights and barely holds an idle.  and sometimes it will all of a sudden run like a charm.

I've checked the TPS, replaced the MAP, timing is on, and checked the fuel system and replaced the fuel filter.  I even changed the TBI gasket after finding a small leak.

 I havent checked the fuel pressure, the codes, injector, ECM,  O2, or the ignition system.

am I getting close? what should I check and spend my money on next? 

here's links I found of what sounds like similar problems.  no follow ups on the troubleshooting tho.

http://www.zukiworld.com/forum/index.php?topic=466.0

http://www.zukiworld.com/forum/index.php?topic=1840.0

I would say in this case it soulds like wires,
also you didn't mention that you changed them

Wild

I would say in this case it soulds like wires,
also you didn't mention that you changed them

Wild

I'll look into getting a new set,  I was at the parts counter today picking up some other ignition stuff but they didn't have my size wires so I'll have to wait till tommorow.

 has anyone else here experienced this due to bad wires? 

If this is a conversion you might want to look at the wires connecting the ecm to the harness(solder only no crimp type) and also the battery connections and cables, I had only two year old battery cables on mine and they were giving me the clicky starter problem, they were the last thing that I cleaned and then replaced when they looked like new,I must of gotten water in the crimp connection of the cable on the starter end of it so I went to side post cables because i'm getting ready to put the winch on my rig and bingo no more problems.

I dont know if you have tried it but I had a bad vacuum leak and it had some of those problems but not as severe
something to chew on
Dustin

today I bought some new wires, cap and rotor, and plugs. the prblem is still there.

I ended up buying a fuel pressure gauge and it read 23 psi. but seemed to stay constant regardless of the problem being there or not.

on the way home the problem got more severe and barely made it home.  power is non existent and I can't keep the motor running without my foot on the gas.  the fuel pressure gauge is still at 23 psi. even with the problem being worse.

regulator?  ECM? fuel pump? I'm losing my patience and even considering dropping the whole project in favour of building up my toyota instead. 

yes it is a swap into a samurai, no the battery cables aren't old, I don't know much else to say. I'll look into the wires, the vacuum hoses have been checked over.

23 PSI sounds very low, I would expect around 36-38psi. 23 could cause very lean running, have you checked the colour of the plugs?

A quick check, yes 23 PSI is too low, pinch
the return line with a pair of vice grips, if
it runs better or even great, you have a bad
fuel pressure regulator, if not it could be a
bad fuel pump.

thanks wildgoody, I just came back from my club meeting and was told by a member to do the same test with pinching off the return line.  I'll keep you posted tommorow.

just to follow up, I pinched off the return line and still came up with the same PSI.  I finally gave in and dropped the tank, replaced the pump.  runs like a charm.  40psi on the dot. 

thanx all for your advice and input!

regards, mike