ohm check the coil wire while you have the meter out. 3000-7000 ohm per foot, is acceptable for carbon core wire.
I'm still leaning towards the EGR.
Martin
After replacing the torn spark plug wires and whatnot, the stumble is not detectable when my foot is on the throttle. The K5 accelerates smoothly and drives like a dream. When I come up to stoplight and I take my foot off the throttle, it stumbles. So I'll be sitting at a stoplight shaking. Then when the light turns green I hit the gas pedal and the shaking goes away.The stumble happens as you tip into the throttle? Less noticeable with a gradual pressure on the throttle, and more noticeable with quick opening of the throttle?
Fixed multible TBI stumbles by fixing the EGR.
Martin
Egr valves are fairly cheap, seems like it'd at least be worth a shot to put a new one on.
Ok that symptom closer resymbals a miss fire at idle.
Which could be as simple as idle speed, or vacuum leaks.
I know you and Rob gave it a thorough vacuum leak check.
Martin may correct. The egr may still be leaking air/exhaust into the intake. A bad egr valve base gasket, warped base, or dirty pintle all could be the source.
Either a new valve, block off plate or manifold w/o egr.
Since you need an emissions test I suggest a new valve. I would leave it disconnected to see if solves the rough idle.
The new valve should be an AC Delco or genuine gm if you can find. Some of the after market valves are to generic and create drivability issues.
Not sure what you are seeing. Is this a glow near the exhaust port ? like a heat glow ?
Boy, that can't be good. Could be the clips on the end of the plug wires aren't gripping the plugs right. If you had anything coming out of the combustion chamber, you'd have additional problems.I didn't see any arcing but I saw a flashing "glow" from some of the cylinders. Almost like I could see the spark going off inside the cylinder somehow.
That implies your wire is not tightly connected to the spark plug and is jumping a spark right there.It was an intermittent flashing glow right where the spark plug wire attaches to the spark plug. It was pretty dim. I tried recording a video and my camera couldn't pick it up at all. I saw it on only a handful of cylinders and the flashing seemed random (i.e. it wasn't constant).
Boy, that can't be good. Could be the clips on the end of the plug wires aren't gripping the plugs right. If you had anything coming out of the combustion chamber, you'd have additional problems.
That implies your wire is not tightly connected to the spark plug and is jumping a spark right there.
Are you sure the connector clicked good?
a little dielectric grease in the boots too.
This may sound stupid, but what color was the “glow”? Was it blue or orange? Blue would be spark arcing, but orange would be either the exhaust manifold getting hot or if the manifold gasket was compromised it could be flame coming from the port. Though it would be a wicked loud exhaust leak noise too.
Under normal driving I wouldn’t expect to see cast manifolds glowing from heat. Don’t get me wrong they get hot, but normally not hot enough to glow unless it’s under a severe load at lower speeds or excessively lean fuel mixture.
I’d do what Wes mentioned about checking the wire connection at the plugs. Then focus on the egr.