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Old 05-28-2007, 04:38 PM   #1
EJRex
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Default Random misfires after clutch install??

It was time to replace the worn out oem clutch, so I bought an RPS and had it installed by a local and reputable import shop. Also had the flywheel resurfaced. Clutch works excellent, very responsive, but now I have a misfire problem and can't figure it out..
Regardless of what gear, I have a "miss/skip" between 2200-2800 rpm, but no cel from that.. and it's very noticeable. It goes away though if I accelerate but that is not the main issue.
When I start to hit full boost, and it only seems to do it in 3,4,5th gears, the car starts bucking/sputtering and losing power bigtime.. I get a flashing p0304 cel every single time and occasionally a p0302. I have checked the plugs, and they are a light brown, almost rust colored (they are iridiums), not fouled or ashen and still gapped at appox .028. I don't see any loose connections or broken wries/couplers. I went back and tightened all clamps (I have a FMIC) and couplers to make sure it wasn't a boost leak.. but I'm running out of ideas.
I suspect maybe the cam sensor, or possibly slop in the timing belt tensioner, but I don't know. Any ideas/info would be greatly appreciated.

Btw- the car starts and idles very well and smoothly, and remember, this only happened AFTER the clutch install, and I've changed nothing except plugs since then.

I have a Cobb AP with a custom map, but I don't think it's map related.
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Old 05-30-2007, 07:59 PM   #2
Ensi
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I've heard of this on a lightened flywheel, hmm, I wonder if the material taken off the factory flywheel was enough to flip a misfire. My .02
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Old 05-31-2007, 03:27 AM   #3
EJRex
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It's possible, but unlikely.. the flywheel had minimal material removed- it was really in good shape, I just had it done for peace of mind.
I think the problem may be more of a mechanical type, but not easy to trace... gotta go through this thing with a fine-tooth comb.
Thanks for the response.
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Old 09-15-2007, 09:28 PM   #4
EJRex
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Turned out the shop hit the turbine wheel (the d/p was removed for room) during the re-install of the clutch/flywheel. The impact broke a piece off the wheel and when I checked, there was some serious shaft play. I couldn't get anyone to fess up about the damage, but the shop did knock the price down a bit, which tells me they probably knew something..

In any case, at upper rpms the wheel/shaft assembly was "walking" and hitting the housing which explains the loss of power and the CELs (I would lose boost when the wheel hit, but still have the excess fuel which was choking the spark and causing the misfire). I replaced the turbo and haven't had a problem since. Just an update.

Last edited by EJRex; 09-16-2007 at 10:28 AM.
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Old 09-16-2007, 12:01 AM   #5
flycaster
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Interesting...that's a first. How did you figure this out, or was this just a lucky find? Digging into the turbo would've been waaay down on the list for me.
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Old 09-16-2007, 10:25 AM   #6
EJRex
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After checking out some other leads, that was what I narrowed it down to.. boost was very inconsistent in the upper rpms.. the boost gauge would fluctuate..although the turbo was relatively new, the issues I was having with performance/acceleration/top end kept pointing me there. I pulled the d/p and sure enough, there was a chunk of wheel missing, and I could move the shaft a couple of millimeters with my finger, so I knew it was walking. Sucks, but I can get it rebuilt now that I have a replacement.
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Old 09-16-2007, 03:16 PM   #7
flycaster
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Quote:
Originally Posted by EJRex View Post
..boost was very inconsistent in the upper rpms...the boost gauge would fluctuate...
Ahh, OK. Regardless, very nice detective work.
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Old 09-16-2007, 07:38 PM   #8
prometheum
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Quote:
Originally Posted by Ensi View Post
I've heard of this on a lightened flywheel, hmm, I wonder if the material taken off the factory flywheel was enough to flip a misfire. My .02
not likely unless they took over 12 pounds off the factory flywheel and even if they did that it wouldn't cause an actual misfire, it would just throw the misfire light
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