Performance Problems

[rkarl89203]

Okay, electrical checks are all good...gonna have to play "clean the pintle...."

Anyone have a good USA source for EGR gaskets?

[Trey05Woo]

gasket costs about 3 bucks or so, try any auto parts store. We are talking a generic gm linear egr mounting gasket.

was the pintle stuck and full of carbon and soot?

[rkarl89203]

waiting for gasket ,,,,no one even LISTS them here in Rockford, IL

[Trey05Woo]

try ordering for a chevy aveo or cavalier, cadillac northstar, any FWD GM 3.1 3100, 3.8 3800, etc... They are exactly the same gasket, and even EGR only difference is the position of the connector on some valves due to harness location. Gaskets are EXACTLY the same however.

Worst case senario:

http://www.daewoous.com if you dont mind the shipping delay...

[rkarl89203]

Good news, found one locally, oddly enuf...at Autozone......went thru all the photos/spec....seems the one for the Suzuki Reno (apparently also a daewoo product) is exactly the same...could be working on it by noon TODAY! ($3.58 + tax)
yayyy

[rkarl89203]

I am perplexed....Treywoo, I am stumped.

I physically removed the EGR valve assembly and checked it.....there WAS some, but not a lot, of carbon buildup both in the open port and the one where the pintle was.

I cleaned it with carb cleaner darn thoroughly. Let it air dry and re-installed it. The CEL went out.....no missing, smooth idle.
Drove it for 1.5 hours, in a wide circle around Northern Illinois. No problem.

I stopped for a Coke at a gas station. Started up the car to go home and it was BACK.....CEL on, flashing CEL under heavy acceleration. I am going to go to Autozone and have them pull the codes again, but I suspect it will be the same....

I am stumped...the pintle moved freely, didn't feel like it was stuck or bound up at all....I am wondering if I don't have a weird off the wall electrical problem to the EGR.....but it LOOKS like the only way to find out for sure is to buy one new and install it ($170)....but if it IS a weird electrical problem it will be a waste of money....

HELLLPPPP

[rkarl89203]

Well, ran the codes, exactly the same as before.

Went to Advance auto. They physically removed cylinder 3's spark plug wire while running--NO CHANGE in engine operation...I think I'm running on THREE cylinders.....

checked the wire to the plug, good spark...turned off car, took plug out....looks black.....took Cylinder 2 plug out, looks tan/white.... the tech at Advance SWITCHED plugs 2 and three....ran fine for a couple of blocks, then flashing CEL again.

I am going to change the plug in Cylinder 2 tomorrow. That's the one that WAS in cylinder 3....if the problem transferred I have a bad plug (latest theory...).....

If that doesn't change anything, the EGR valve will be ordered.

[Trey05Woo]

Ok so replace the EGR valve... If you performed all the system checks i listed, then you have isolated the problem to the valve itself. Obviously the car ran fine and to specs until the mil came back on and EGR codes were present again. OBD is telling you were the problem is located, egr and there is only one component left.

If your still in doubt, take some duct tape and tape the orfices of the valve shut, reinstall it and leave it disconnected. run the car and see if the misfire disappears. Keep in mind you may experience some pinging and or predetonation since egr is bypassed and not cooling the cylinders...

[rkarl89203]

Well I sucked it up and REPLACED the EGR valve.....($184!!!!)....

No EGR codes, and the engine is idling and accelerating much better......

BUT

I still have the flashing P 303 Cylinder 3 misfire CEL.....at almost any speed.....

I measured the resistance in the wires....all about the same.....All new plugs.....

TONS of spark from Cylinder 3 wire when wired end moved to the chassis......

I'm really stumped here.....

Trey...help!


(clogged injector? bad cylinder 3 injector sensor?...I'm at a loss...can't even rule the coil pack out....)


EDited to add: Just bought another set of REALLY high end plug wires....and installed them.

I am now $320 into this problem. Will eat dinner and then drive the **** out of it and see iif there is any change.....

[rkarl89203]

Well, I'll be damned!


Drove the Woo 45 miles, at speeds approaching 80 mph, and the CEL did not flash even once.

Idle is steady, performance is AMAZING.....

Spark plug wires and EGR, it appears it was.....

sheesh//we'll see........but hope springs eternal......

[Trey05Woo]

Sorry man just been swamped these past couple of days here at the shop...


But good to see that atleast the EGR system is back on track.

As for the wires Im curious what was the resistance reading of cylinder number three compared to cylinder #1? and when you mean good spark you mean

WHITE
AND ARCS A GOOD INCH OR MORE?

Anyways, lets see if the car stops acting up, but if it does not can you post pics of the cylinder number three spark plug?

[rkarl89203]

Appears to be fixed...2 days, 150 miles now....no CEL.....

Keeping an eye on it.....

Good performance, quiet, great idle speed....

I'm shocked and relieved.....

[Trey05Woo]

what brand wires were the first purchased?

[rkarl89203]

First Wires were Duralast from Autozone.....most recent were Autolite Professional....that seems to have fixed the misfire problem....

Going on 3 days now, no CEL........

whew!

[Trey05Woo]

ohhh the d word lol. yea i tell everyone to stay the fuck away from duralast/autozone... they just sell subpar shit imho...


you should have gone for some packard brand wires which is the oem brand for daewoos...

anyways yea sounds like your problem is solved erg and mickey wires from autozone