95 Talon TSI Turbo FWD

[rwh1959]

I've been working on this Talon, ProDate 11/94, the engine was recently replaced, 2/02, with a longblock that was rebuilt by a long time trusted custom rebuilder. Most major components were replaced except manifolds, coil pack, injectors, map sensor, ignition control module and ignition switch. Went through 2 TPS's in 3 months, the only initial problem, and does not seem to be related to the current problem.
Then last summer the car developed an intermitent starting problem, sometimes it would just sputter, (like a engine with very poor compression), sometimes not start at all, and a set of spark plugs would only last 4-5 months. Replacing the ignition switch seemed to resolve this problems.
Now a new starting problem: after driving the car, allowing it to reach normal operating temp, it refuses to restart, (the car runs great until you shut it off, excellent power, very responsive, cylinder balance test all with in 4.2%, engine temp just to the right of center, no complaints at all, until I shut it off). I do have 3 sort of work-arounds:
1)Letting the car sit 60-90 minutes will most often resolve the problem. 2)Disconnecting and reconnecting the plug on (not sure Eagle calls it this), the ICM, (ignition control module), will sometimes resolve the problem. (I've tested the module using the procedure in the manual, using a multimeter, and the results are always well within specs. I've also performed wiggle tests and resistance tests on the wires, with no problem detected.)
3)Unpluging and testing, or just reattaching, the connector at one of the injector will also sometimes resolves the problem.
The current problem is simular to the one last summer in that on some mornings the engine seems to sputter at first, (though this time the spark plug are clean), then if I shut the engine off, and just wait 5 seconds, (nothing being done under the hood or inside the car), then try to restart, it starts right up and runs great. My thought is that the ICM is still the culprit, an internal error that is sometimes resolved by just unplugging and reconnectiong either the ICM connector or a fuel injectors connector. But I hesitate to replace this module do to its high cost.
Thinking it could be some type of ground problem I've added additional engine and body grounds
When the engine fails to start, (restart hot), it sounds like weak spark, or possibly flooded engine, but plug are clean and coil and coil wire test results are within specs.
And the problem seem to be getting steadily worse, colder weather may be playing a role? Or maybe the intermitent part is finally about to become the failed part. (And the car will answer my question.)
Any thoughts would be helpful and appreciated.

[MrZ]

Are you getting any fault codes in the ECM?

Mark

[MuttedtsiAWD]

Replace the coil pack