Rep Power: 0

Alright. I no longer have any idea what's going on with this car. So, if you know what might be happening here, I'm all ears:

I've got a great little 1991 Civic DX, 1.5L manual. It's never let me down and I love working on it.

Stalled on the highway a couple weeks ago and I couldn't get it re-started. Over the years, it's had a bit of a personality where it chugs and occasionally stalls at a low idle, or when very slowly accelerating from a stop. If I'm sitting still, I'll turn the key to full off, give it about 30 seconds, and it'll start right back up. For whatever reason just re-starting without turning off never seemed to work.

So since it stalled on the highway and I wasn't able to get it started at all, here's the list I've replaced or completed:
- main relay
- fuel filter
- plug wires
- spark plugs (the old ones were due, but not overdue, and all four were pretty fouled with burned oil and had oil in the wells)
- spark plug well o-rings and valve cover gaskets
- and fully charged the battery

At this point, if I let it sit until it's cool, it'll start right back up with no trouble. Then once it warms, it starts to run a bit rough, eventually chugs, stalls, and then I can't get it started again - spins a few times, then kinda sticks, then spins a few times, and kinda sticks again.

Any ideas??

 
Rep Power: 228

The fact that you have to turn the key off and then back on could point to the fuel pressure not being stable. When you turn it off and on the fuel pump primes the lines to create extra pressure to start the vehicle.

Check your fuel pressure with a rented test kit. If it is low check the fuel pressure regulator and the fuel pump.