Corvair - Turbo :: 1964 - Occasionally Stalls And Can Be Hard To Start


Jun 4, 2012

Our new '64 Corvair Turbo car had been running pretty smooth, but occasionally stalls and can be hard to start. There has been noticeable flooding out of the carb bowl (single barrel Carter going into turbo). It has an electric choke that seems to be working correctly. The choke butterfly is closed when cold and opens as it gets warm.

Friday we drove to next town and it ran perfectly smooth but stalled when we got there, was very hard to start and ran super rough all the way home. It would not idle, had to hand brake at stops to keep from dying. It was normal temprature (400 degrees). Choke was wide open.

The next morning I started it easy, choke on (closed), but when it got warm it stalled and died. Then flooded fuel out of bowl.

I am only guessing... but seem like carb is tuned to run cold with choke on and is either running terribly lean or rich once it is at temperature.

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Is it possible for a faulty diverter valve to dump the boost overboard and cause the turbo, and engine hp, to surge? It almost feels like I let my foot off the gas for a second or two (i.e., engine power is very peaky).

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1. Initial Issue from March to October is hard starts; it would take 15 minutes or more to start car; it would be longer sometimes in cold weather.

2. Car would have erratic idle after startup; car reaches operating temperature before movement; car would bog down in idle and die only in reverse; initial acceleration from takeoff is slow;

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4. Sometimes in rain or wet weather, car would stall and sometimes backfire; Distributor Cap is normally changed.

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6. Car starts now, idle is not erratic; car would bog down in idle and die only in reverse; you barely tap gas to keep from dying in reverse; initial acceleration from takeoff is slow; car

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lowering; sometimes car stalls at braking; gas is sometimes tapped slightly to stop stalling.

7. During idle or operation, sometimes coolant will boil in reservoir; toggle fan brings temp down to normal in between fan cycles; toggle fan keeps coolant temp normal in really hot weather.

The following parts have been changed and are still prominently new:

-Ignition Coil
-Spark Plug Wires
-Spark Plugs
-Distributor Cap (Initially Sealed With Sealant, Condensation Issue When Raining Causes Stalling)
-Rotor Button
-Condensation Cap For Distributor Cap (No Need For Sealant Now)
-K&N Air Filter
-Turbo Intake Hose (Original Had Disentegration In Spots)
-Exhaust Manifold Gasket (With New Locking Nuts and Sealant On Manifold Side, Not Block Side)
-Power Stage (Ignition Module or Ignition Stage Amplifier)
-Engine Coolant Temperature Sensor
-Gauge Temperature Sensor
-Knock Sensor
-All Vacuum Hoses
-All Coolant Hoses (Including Oil Cooler Hoses)
-Fuel Pressure Regulator
-Oxygen Sensor
-Catalytic Converter (Honeycomb In Original Rattles, Discovered Gone When Removed)
-Exhaust Resonator/Central Muffler (Original Damaged By Honeycomb, Sounded Like Broken Glass, Baffles More Than Likely Clogged)
-Idle Air Control Valve
-Starter Solenoid (Starter Tested Good)
-Power Brake Booster (Original Replaced, Failed 2 Out Of Three Brake Pedal/Vacuum Tests)
-Battery
-Radio Suppression Relay
-Throttle Position Sensor
-Fuel Filter
-Timing Belt and Tensioner
-Crankshaft Position Sensor (Last In Chain, Resolved No-Start For Now)

The following are checkpoints, mods, and maintenance:

1. Modded Airbox for more airflow, no codes present from OBD before or after

2. Cleaned MAF Sensor with MAF Sensor Cleaner, no codes present from OBD before or after

3. Checked EGR Valve - Diaphram not broken, free movement, appears functioning

4. Had EGR Pipe Rewelded - Pipe broke from connection to throttle body, completely sealed and functional, Minimal Carbon Removed

5. No codes from EGR temp sensor before or after

6. Checked EGR Vacuum Controller through OBD - appears functional

7. Checked Fuel Pump - Repaired frayed hot wire, sealed, pump fully functioning

8. Checked Fuel Pump Relay - Functioning

9. Properly adjusted Idle Air Speed - Steady Between 700-800 RPM

10. Checked EGR Pipe to Exhaust Manifold - Minimal Carbon Removed

11. Cleaned Throttle Body with Throttle Body Cleaner - No Soot/Carbon exiting system

12. Created Toggle with Fuse in between connection, connected to slot in fuse box, cuts off with car, slight battery drain issue before and after installation

13. Checked oil in case - oil change still new, no milky appearance suggested head issues

14. Removed and cleaned breather box - no oil deposits clogging operation

15. Checked charcoal canister - stalling in reverse happens with and without it connected

16. Checked muffler during disassembly of exhaust system - no honeycomb/debris present during testing

17. Car is at Top Dead Center - Timing

18. Fuel Injectors tested fine with OBD and Pressure present at rail

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-Charcoal Box
-MAF Sensor (No Codes)
-EGR (No Codes)
-EGR Vac Controller (No Codes)
-Compressor (No A/C, issue with stalling is unrelated)
-Power Steering Pump (Slight squeaking on rotation, PB Blaster in bearing area confirms, issue with stalling unrelated)

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