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New Overhauls, New Acceleration Problem

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Old Oct 11, 2020 | 07:05 PM
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cppeabody's Avatar
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From: Fredericksburg, Va
Default New Overhauls, New Acceleration Problem

Dear wonderful people!

This forum is amazing and I have been able to learn and do so much on my Crossfire! I'm at a point where I need help:
  • I own a 2005 limited, N/A 6-speed manual with ~115k miles. I purchased it about 5 years ago with ~50K miles and it has been running great. Fast forward to now, and things have obviously run their life on the car, so to pass inspection and save $$$ (I'm an elementary music teacher, so affording labor costs is out of the question for me).
  • THE PROBLEM: NOW THERE IS SURGING/LOSS OF POWER FEELING THROUGHOUT THE 35-65 MPH BAND ON GRADUAL ACCELERATION/STEADY SPEED
  • THE CATCH: THE PROBLEM DID NOT EXIST BEFORE I DID THE FOLLOWING
  • CONTEXT: the repairs were driven be loud engine noises/shaking, weird smell from engine bay+other dings for the inspection
  • ***INTERESTING NOTE***: THE CAR HAS ALWAYS HAD LOUD/INTERMITTENT TRANSMISSION NOISE AT IDLE (UNLESS THE CLUTCH IS DEPRESSED)
  • THE REPAIRS:
    • Replaced both front wheel hub bearings (new inner/outer bearings, new races, new grease, new inner seal) BONUS: CREATED TOOL THAT MADE THE RACE REMOVAL A BREEZE!
    • Replaced valve cover gaskets
      • THIS was interesting. I never went through to check the bolts since when I had purchased it, and when I went to replace the gaskets, almost EVERY bolt was finger-tension loose, so i can only imagine that I had been driving the car for years with them like that, and without knowing.
    • Replaced air intake filters
    • Replaced all spark plugs
    • Replaced front tires (balanced)
    • Replaced and bled all brakes
    • Replaced idler pulley
    • Replaced tensioner pulley (JUST the pulley)
    • Replaced alternator
    • Re-applied old belt
      • I had a new one, and wanted to see what the difference was with the new pulleys and such done already to see if I could track down any other noise
        • TEST DRIVE: INCREDIBLE NEW POWER!!! THE CAR HAS NEVER FELT THIS GOOD! Which I think could be due to the old plugs, and borderline complete pressure leak with such loose bolts on the valve cover gaskets
          • ASSESSMENT PROs: much diminished engine noise, smell completely disappeared (bad alternator symptom)
          • ASSESSMENT CONs: still louder than normal engine noise (stethoscope has more than comfortable noise from tensioner pulley) , and new surge/loss feeling (stated above)
  • NEXT REPAIRS:
    • Bled transmission slave cylinder line
      • TEST DRIVE: CAR FEELS EVEN BETTER AND TIGHTER IN RESPONSE!
        • ASSESSMENT PROs: engine noise further diminished, almost non-existent after slave cylinder bleeding (thoughts on this???); stethoscope traces noise to AC compressor bearing; ALSO, no bearing noise. but noticeable loose water pump pulley
        • ASSESSMENT CONs: acceleration surge/loss still present; tensioner pulley noise still present, but much less than before
  • NEXT REPAIRS:
    • Cleaned MAF Sensor and housing (not much grime before hand)
    • Cleaned Throttle Body (not much grime, but a little dirtier than MAF)
    • Disconnected (-) battery terminal for 30 min
      • TEST DRIVE 1: ZERO NEW ENGINE NOISE, ZERO TRANSMISSION NOISE AT IDLE, ACCELERATION SURGE/LOSS ONLY AT 45-55 mph BAND DURING GRADUAL ACCELERATION/STEADY SPEED
      • TEST DRIVE 2: ZERO NEW ENGINE NOISE, INTERMITTENT TRANSMISSION NOISE AT IDLE, ACCELERATION SURGE/LOSS ONLY AT 45-55 mph BAND DURING GRADUAL ACCELERATION/STEADY SPEED
      • TEST DRIVE 3: ZERO NEW ENGINE NOISE, HISTORICALLY PRESENT TRANSMISSION NOISE AT IDLE, ACCELERATION SURGE/LOSS EXPANDS TO 35-65mph BAND DURING GRADUAL ACCELERATION/STEADY SPEED
        • ASSESSMENT PROs: no diminished performance or new engine noise, even with old belt used
        • ASSESSMENT CONs: acceleration problem still present
  • NEXT REPAIR:
    • Performed the throttle reset *procedure* (depress gas pedal for 5 seconds with key "on" but not start; turn key off but leave in for at least 2 min)
      • TEST DRIVE 1+2+3: same as above
        • ASSESSMENT PROs+CONs: same as above
  • NEXT REPAIR:
    • Replaced old belt, let car idle for about 5 minutes
      • TEST DRIVE: same as #3
        • ASSESSMENT PROs: virtually all engine noise disappears with new belt, other than A/C bearing; tensioner pulley noise virtually disappears on stethoscope
        • ASSESSMENT CONs: acceleration problem still present between 35-65 mph during gradual acceleration/same speed
  • WHERE AM I AT NOW?
    • I have not yet replaced the water pump (part just came in) or the AC compressor clutch
    • I have a new harmonic balancer and nut to install. I originally thought the degree of engine noise and shaking was due to a bad balancer, but all of that has basically completely disappeared after the pulley repairs, but I still intend on doing it.
    • ZERO codes have popped throughout the process, except for the 410 code today, so I'll be looking at the RCM to assess the solder repair soon (COULD THIS HAVE AN EFFECT?)
    • I religiously change the oil every 5k miles with the recommended Mobile 1 and use a fuel system cleaner each time
    • I only every use premium
    • again, the acceleration problem has NEVER EXISTED until now, even with the old plugs, loose valve gasket bolts etc. Other than that and the transmission knock that has always existed, everything is basically good to go.
I absolutely adore my car and would hate to have to let it go. I have searched the threads as much as possible for a solution to the acceleration problem that I can tackle and fix on my own. I'm not above admitting that I may have missed something (hopefully something obvious!), and I would so, so appreciate any guidance you can give me.

Thank you!
 
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