hi guys whilst searching this subject on Google i found this hope is some help for every who has tried everything.
Hi everyone. First of all, great forum. I have learnt a lot of technical specs about my car just from reading your posts. I had the same curly problem as most people here. I have a 1999 VT and as you have mentioned stalled when it idles for extended periods in hot weather. Wait a while... and it started again for a little while.
I had replaced the Crank angle sensor twice, the Cam angle sensor, the DFI module and coil packs, new leads, new plugs, fuel filter, fuel pump, swapped the computer beside the steering wheel, whichever it is ... rewired the plug to the DFI module but the problem still persisted. I have been following this thread now for maybe 2 months trying to fix the car, or thinking of ways to smash the s--t out of it. Over this time, I've been driving with the computer set to show actual temperature so I could gauge at what temperature it begins to stall.#
To do this hold the "arrow up" button and "mode" button simultaneously, and start the car. Release them when the car starts and press the mode button a few times until you see a small "T" on the left of the screen, and a number on the right side of the screen. The number displayed is a digital readout of the actual engine temperature. Sometimes it would cut out at 82C, 86C, sometimes as high as 96C or even 106C. I'd checked my fans and they actually do cut in at 104-105C but the car would stall before this almost always.
Yesterday, being a hot day in Sydney and going to work .. the usual happened and it began to stall. By chance, I moved the wiring of the DFI Module harness which is routed near the thermostat housing. There is a junction of wires there... some lead from the airflow meters and the sensors at the top of the engine, and they join with a group of wires from the cam angle sensor and the crank angle sensor. There is also a pair of solo wires which lead to the temperature sensor.#
At any point, I moved these wires off the thermostat housing and low and behold... it did not stall again for another 5-6 kilometers in peak hour traffic. Possibly because through vibrations the harness touched the hot housing again. This morning, I looked at the wires in this harness and found slight horizontal cracks. I rewired the cam and crank angle sensors from maybe 5-6 cm above the sensors all the way to the DFI module harness AGAIN and also purchased a thicker diameter plastic heat shield, and enclosed all the wires in this harness in 2 heat shields; one inside the other - so they do not even touch the DFI base plate ... and ... PROBLEM SOLVED.
For those who as I did have replaced everything listed in this thread and the problem persists ... it's a good bet to have this section of wiring checked by a sparkie or do it yourselves. Today was a hotter day than yesterday, and it did not stall once ...#
At least now I can get the Air-con re-gassed and finally use it !!!
My car has done 270,000, and prior to 2 odd months ago... it never skipped a beat. Apart from brake pads and service items, I have not done any major work to it at all.