Alright, all new plugs, wires, coil packs, ignition module (ouch!), and injectors still working. All new parts are working. Timing varies more than a few degrees. Engine runs a bit on the hot side, not enough to trigger fan. Engine stumbles like it's misfiring, but is able to partially compensate. Still vibrates and exhaust is chug-chugging Am I looking at a lifter problem? Rocker arms need adjusting (messy, but done it before, way back with aftermarket roller tip rockers)? If you think this belongs in another forum, PLZ let me know!!

Adjust your rockers and see if that helps, if you have an exhaust rocker adjusted too tight, you'll burn an exhaust valve and that MIGHT make the engine run warm, along with it not closing completely which would probably cause your stumbling issues.

Popped the valve cover and found a couple o' rockers a bit skewed (CRAP!!!!). I musta not had them tightened right or something. New pushrods all around and adjusted rockers -- should they just be barely snugged down? Big question, 'cause I think being too loose led to them gradually being off kilter this time. They're aftermarket roller tips. I did the whole half-turn more once the push rod couldn't be rotated, then about a quarter turn more to silence the slight looseness/rattle. Seems that should keep them 'in line'. I unhooked the battery to reset the computer. Car still ran poor, but sounded like it wanted to smooth itself out. Rechecked the plugs, and they are all sparking quite boldly. BTW, Thank you SOOO much for replying! Gettin' kinda scary figuring this on my own. Money's tight, and I am on the verge of loosing my confidence.

What sort of nuts are you using to keep the rockers down? do they not have jamnuts in the center to lock them? And if its still running crappy, you MAY have a burnt valve, if I remember right, you need to do a compression test on all the cylinders to make sure. although, that would also tell you if you have worn rings too, so its not totally conclusive. Has the CEL lit up at all? And from you saying your timing varies, you MAY have a loose timing chain.

Rockers came with metal lock-nuts. I don't believe they loosened by themselves, there's a moderate bit of resistance during adjustment. They should be almost loose when the valve is closed, yes? Takes a good hard wiggle to move them at all. All the new plugs were very carbon-fouled, a result of the rich fuel mapping. Mapping is leaned out to about where it used to be. I'll have to see whether it'll clear up by itself, prob'ly got a lot of carbon on the valves, to. Gonna SeaFoam it on Wednesday one way or another. Compression was still excelent before all this sh!t happened. Timing chain is still relatively quiet. Engine smooths itself out at highway speeds.

Id say get it all cleaned up, sea foam, and either clean up the plugs or get a set of new ones.

I had this problem when i re-installed my 1.6's last time. I did it, it was FREEZING and I was about 5 hours past schedule, about 2am I was finishing. I didnt tighten them up right. All I was trying to do was get home so I ajusted them untill it turned over. in 20 miles i burned maybe 1/4 tank. and worked on getting them fitted right the next day. I didnt check the plugs or anything. The car eventually couldnt run on the plugs under a load, just would up and die.

LOTS of carbon in the system. Got it all worked out and its running golden again.

The cheapie metal locknuts, or the nice ones that have the little allen screw in the top that you tighten down to jam the nut in place after adjustment? The cheapies wear out after a time or two of adjustment, the jamnut kind don't.

Negative all around, Greg. High grade locknuts, no nylon inserts, no jamb nuts. I highly doubt these worked their way loose. My stupidity caused that problem. Anyway, I've thrown in the towel and am letting the shop fix it. Better training, fancier electronic toys, should find something. Gonna kick myself either way; $20 part I coulda done, or a $2,000 rebuild. I'll let y'all know what they find.

Sorry for the delay, but it's been one helluva week. Turns out there was a burned valve at #4, leading to no compression. Either a new head, and maybe another year, or a new engine and sink more $$$$ into the 'pit'. I went with option 'C', new car. We were restructuring our finances and were able to squeeze in a new car, a G5 GT. I may not have torqued the rockers down some months ago, leading to the burned valve, or it just gave up the ghost by itself. Sad to see my ol' 'Fire go, but I was sorta backed into it. Oddly enough, it was similar circumstances at the exact same time of year when I traded in my Escort EXP in for the 'Fire. Talk about the circle of life! LOL