At 05:36 PM 8/19/2010, Scott Daniel - Turbovans wrote:
>I only spent a few minutes looking at it and discovered the stud that holds
>the right side of the cross-over heater circuit metal pipe on top of the
>engine, was broken off, resulting in a nice hole in # 2 intake runner.

Classic 1.9l problem, and the very devil to find if you're not
specifically looking for it.  Until you wiggle the coolant pipe
everything looks completely normal.  The tear in the pipe fits back
together perfectly until the engine starts vibrating, and you get a
nasty intermittent "just not right." effect.  After all, who would
think that the studs in the intake headers would tear out so easily?

Fixed mine with some RTV gasket compound, a piece of tin can to cover
the hole, and a hose clamp to secure the whole thing including
crossover pipe together.  Had to tighten the clamp a little after ten years.

Yours,
David