Hesitation and clicking when accelerating

[racey83]

Hi My 2002 M49 1.6 16v petrol multispace has suddenly developed an annoying fault. When accelerating it is intermittently hesitating until past 2500 rpm and whilst this is going on there is a rapid clicking (in time with the hesitation). The clicking is coming from the fusebox area next to steering wheel.

My initial thinking is fuel pump relay but anyone else who has had similar problems may know better?? Any suggestions appreciated before I go down the rabbit hole of trying to diagnose this.

Thanks.

[Kieron G]

Will it do the same while the car is stood and engine taken up to 2500?
If so you could put finger tip on each relay (if it is a relay) or just find out exactly where clicking is coming from.

[racey83]

Will it do the same while the car is stood and engine taken up to 2500?
If so you could put finger tip on each relay (if it is a relay) or just find out exactly where clicking is coming from.

Yes it will do it stood, sharp throttle sets it off. Will try your suggestion thanks.

[racey83]

So had a poke about this morning and it does it now even while idling, and the clicking is coming from within the BSI. 

Then I took it to get some shopping then the fun really started.... Raining and condensated so I switched the heated rear screen and wipers on, this really upset it. Didn't die completely but hesitation bad below 1500rpm and wipers kept stopping and starting, heated screen turning itself on and off. Putting the hesitation down to immobiliser as BSI controls this according to the book.

So I'm confident its the BSI that is the problem question now is is it plug and play or is there coding etc when I find a replacement?

[racey83]

Searching the forum has answered that last question. Gonna try BSI reset then if that fails start sh*tting myself.

[RattyCortina]

I believe the BSI can be opened up and individual relays replaced.

[racey83]

Will look into that but if that's a no go then gonna need a new one as BSI reset did nothing to improve the situation. does anyone know where maybe able to repair or replace and clone my BSI? Pretty desperate now as really don't want to bin the car just for this.

[racey83]

Well having read a number of posts on the forum now I've had time to look properly I'm wondering if I've got water ingress as the night before this kicked off I was in Stranraer on holiday and it rained biblically.

@RattyCortina, going to take the BSI off on Friday morning and open her up and see what's going on inside, clean, dry it out if necessary and test relays as I've seen ffrenchie's post and feel confident I can do this.

Fingers crossed.

[brodfather11]

This may give you a little help , it shows how to remove the BSI


https://youtu.be/qJ1mumWunGI

[racey83]

Got it open, no water or dirt.

2 diodes are no good.

Don't know what the 3 beige jobbies are in the bottom right of pic, whatever they are they open circuit both ways codes are mck 215 nsc 223 any ideas? Thanks.