This question is going to be about my Pinto's cousin, a 1982 Ford EXP, 1.6 carburated engine. For those that forgot about or never knew about EXP's, it is a 2-seat, sportier, hatchback version of an Escort. My problem: There are times while driving it begins to stumble and feel like it's running out of gas. It would be running perfectly and then the stumbling begins. I have been able to nurse it home, but it has also died on the side of the road. Other times it will run perfectly, then I make a stop for gas or to go in a store and when I start it back up it will start and run, but only for a very short distance, then it exhibits the out of gas symptom. It did it to me last Fall after driveing 120 miles perfectly. I stopped for gas and 1/4 mile down the road it die. It happened last weekend on it's first outing of the season. Drove about 15 miles to Lowes, bought a few items, got in, started, but never made it out of the parking lot. Left it there, came back 4 hours later, it started and drove home fine. This has been the MO for this car. I've had it for three years reestoring it so I have no history from the past. It has NEW fuel tank, existing rigid supply, return, and vent lines, but new rubber fuel hoses to connect the rigid lines as it was from the factory. New fuel pump and pushrod (I have put two different new furel pumps in it and still have the same issue). Carb was professionally rebuilt by a former employee of Pony Carburators. New factory-style fuel filter. I did re-use the sending unit/fuel pickup. I cleaned the filter that pushes on the pickup tube that goes into the tank. I had a Wix see through in line fuel filter before the factory filter but removed it thinking it was causing too much resistance for the pump. No change. When I had it in it showed good fuel flow when running well but barely a trickle when it was having the stumbling or no start condition. It will kick off with starting fluid but won't stay running so I believe it to be a fuel isse, not an ignition issue. When it runs it runs very well. It's usually out of the blue or after a quick stop for gas or store when it has a problem. If it sits long enough it will start and run. Once I had it towed to the shop I take cars to and when it got there it started and over the week they had it it started every time. They suggested changing the pump, even though it was new but it continued to have the same problem.
I suspect it could be one or several of the following:
- two defective fuel pumps (not likely)
- fuel lines (hoses) collapsing due to pump suction causing low flow
- Fuel hose crushed between the tank and floor of the car causing low flow
- vapor lock (has always been relatively cool out when it happens but maybe underhood temps are the culprit?
- is there a fuel shutoff solenoid on the carb that kills flow?
I know this is a long post and not about a Pinto but I'm hoping one of you has had a similar experience and can share what you did to fix. I'm afraid to take this thing out on the road thinking it's going to leave me stranded.
Thank you in advance for any advice or wisdom you can impart.
Rob