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Driveablity issue (now with updates)

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Truck is a 1990 454 auto, one ton crew cab that is stock. OK, so I've had a check engine light forever (code 42,) I never paid it much never mind because the truck ran ok, not good, but ok. I did a tune-up on it and O2 sensor when I got it (maybe 10 thousand miles ago.) If I floored it to jump on the freeway and get up to speed on a short on ramp it would miss, pop through the intake and generally be low on power. I threw a coil on it for giggles and ****s to see if that would fix it; it didn't. And with it being little more than a winter comuter, i could live with this. Well, with putting the bed on it I'm taking more pride in the truck and I want it to run (and work) like it should. I want to get this thing straightened out.

Recently the truck developed a bad hesitation when taking off, say from a light, it feels like the motor cuts out, then catches, then cuts out, then catches. This came to light around the same time I cut the muffler off due to it having a hole on the top directing the exhaust at the floor, heating the floor and damn near starting a fire. I have since replaced the muffler and the truck now only hesitates like this on occasion.

Poking around under the hood the other day I was spraying around some brake cleaner looking for vacuum leaks around the TB base, I couldn't get the idle to change. I capped the vacuum port where the vacuum line going to the vacuum ball because those lines were shot and colapsing. Pulling the line off had no effect on the idle. After capping the port and letting it idle for a few minutes, pulling the cap off caused an increase in the idle rpm. Plastic lines and rubber boots for the vacuum lines feeding the MAP, and EGR look and feel good from what I can inspect of them without taking them off. After doing this the truck developed a single cylinder missfire at idle and light to moderate load. I checked the plug wires at the distributor and at the plug, and hit them with a spray bottle. None of this exposed any faults.

Last night working to diag the CEL and code 42 I began doing the test as outlined in my factory service manual. In that test it has you ohm the ground circuit for the ESC module at the ECM, and tells the resistance should be less than 1000 Ohms. And if not it condemns module, the circuit or the connection. My test found 900 Ohms resistance. I pulled off the module and the white paste was still pasty with no green fluff or corrosion under the cap, the distributor is an aftermarket unit of unknown age and make; but shows no signs of age or defect.

This is where I had to stop last night. Saturday I want to tear into it more. I would like to Ohm out the EST wire from the ECM to the connector. Should I be content with my 900 Ohms of resistance? It is under the spec of 1000, but not my much. Should I throw a module at it for piece of mind? Any brand preference? Should I just keep going with the test? help!
 
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Check your fuel pressure is good. Then test the EGR properly. More than likely the EGR is your issue though. Code 42 may be an issue with the pickup coil in the distributor or with the knock sensor as well.
 
Low fuel pressure will cause a lot of these issues as well as EGR sticky/open and vacuum leaks.

Brake cleaner just does not work anymore like old cleaner and starter fluid did for vacuum leaks. Use a propane torch which has fuel that will raise idle if vacuum leak is found. For a test? Spray brake fluid down TBI when running... does engine rev up... no... spray propane down TBI when running, does engine rev up... yes!

The aftermarket distributor and EST/ICM is probably the cause of code 42. Code 42 will also set when the bypass wire is disconnected to set timing. Always use a AC/Delco EST. All aftermarket EST modules change timing and who knows where or which way?

There's a good chance this 454 has no knock sensor or ESC module! Many BB did not come with them, instead GM put in an spark advance table that would never knock and is so safe for idiots towing.

Another serious issue with small cap TBI distributors is the cap. Look in there and see if button still has spring load? Many are just hanging and cause all sorts or arcing around cap, I'm sure this is not good on EST module either having 40k volts floating around.
 
Truck is a 1990 454 auto, one ton crew cab that is stock. OK, so I've had a check engine light forever (code 42,) I never paid it much never mind because the truck ran ok, not good, but ok. I did a tune-up on it and O2 sensor when I got it (maybe 10 thousand miles ago.) If I floored it to jump on the freeway and get up to speed on a short on ramp it would miss, pop through the intake and generally be low on power. I threw a coil on it for giggles and ****s to see if that would fix it; it didn't. And with it being little more than a winter comuter, i could live with this. Well, with putting the bed on it I'm taking more pride in the truck and I want it to run (and work) like it should. I want to get this thing straightened out.

Recently the truck developed a bad hesitation when taking off, say from a light, it feels like the motor cuts out, then catches, then cuts out, then catches. This came to light around the same time I cut the muffler off due to it having a hole on the top directing the exhaust at the floor, heating the floor and damn near starting a fire. I have since replaced the muffler and the truck now only hesitates like this on occasion.

Poking around under the hood the other day I was spraying around some brake cleaner looking for vacuum leaks around the TB base, I couldn't get the idle to change. I capped the vacuum port where the vacuum line going to the vacuum ball because those lines were shot and colapsing. Pulling the line off had no effect on the idle. After capping the port and letting it idle for a few minutes, pulling the cap off caused an increase in the idle rpm. Plastic lines and rubber boots for the vacuum lines feeding the MAP, and EGR look and feel good from what I can inspect of them without taking them off. After doing this the truck developed a single cylinder missfire at idle and light to moderate load. I checked the plug wires at the distributor and at the plug, and hit them with a spray bottle. None of this exposed any faults.

Last night working to diag the CEL and code 42 I began doing the test as outlined in my factory service manual. In that test it has you ohm the ground circuit for the ESC module at the ECM, and tells the resistance should be less than 1000 Ohms. And if not it condemns module, the circuit or the connection. My test found 900 Ohms resistance. I pulled off the module and the white paste was still pasty with no green fluff or corrosion under the cap, the distributor is an aftermarket unit of unknown age and make; but shows no signs of age or defect.

This is where I had to stop last night. Saturday I want to tear into it more. I would like to Ohm out the EST wire from the ECM to the connector. Should I be content with my 900 Ohms of resistance? It is under the spec of 1000, but not my much. Should I throw a module at it for piece of mind? Any brand preference? Should I just keep going with the test? help!


until shown otherwise, ignition modules are one I always like to go AC Delco... off brands from the parts stores have been known to fail prematurely...


off idle throttle issues tend to be EGR related... you can ohm out your plug wires too...
 
Check your fuel pressure is good. Then test the EGR properly. More than likely the EGR is your issue though. Code 42 may be an issue with the pickup coil in the distributor or with the knock sensor as well.

Low fuel pressure will cause a lot of these issues as well as EGR sticky/open and vacuum leaks.

Brake cleaner just does not work anymore like old cleaner and starter fluid did for vacuum leaks. Use a propane torch which has fuel that will raise idle if vacuum leak is found. For a test? Spray brake fluid down TBI when running... does engine rev up... no... spray propane down TBI when running, does engine rev up... yes!

The aftermarket distributor and EST/ICM is probably the cause of code 42. Code 42 will also set when the bypass wire is disconnected to set timing. Always use a AC/Delco EST. All aftermarket EST modules change timing and who knows where or which way?

There's a good chance this 454 has no knock sensor or ESC module! Many BB did not come with them, instead GM put in an spark advance table that would never knock and is so safe for idiots towing.

Another serious issue with small cap TBI distributors is the cap. Look in there and see if button still has spring load? Many are just hanging and cause all sorts or arcing around cap, I'm sure this is not good on EST module either having 40k volts floating around.



until shown otherwise, ignition modules are one I always like to go AC Delco... off brands from the parts stores have been known to fail prematurely...


off idle throttle issues tend to be EGR related... you can ohm out your plug wires too...


Mark, you raise good points about using propane to test for vacuum leaks. I will add this to my to-do list for Saturday. I used to do this all the time working in garages and forgot all about it. Looks like I've lost some things since I've stopped working on cars and moved to heavy equipment! Thanks for the reminder! I like this idea better than brake cleaner or starting fluid. In the event of a backfire, I think it is much safer to spray a gas than to use an aerosol liquid.

I snagged a module off a 350 (a GM one and it was free) and some basic research tells me they are all the same. CAN ANY ONE VERIFY THIS!?!?!

My 454 does have a knock sensor and an ESC module. I have a brand new knock sensor that I will be installing, can anyone tell me if these go right into a water jacket? I do not want to take an unexpected bath. I'll check the button on my cap and make sure it's springy. It's an Accel cap and rotor.

I have not checked fuel pressure, but will this weekend. The truck has two new fuel pumps in it; although I only started using the left tank a few weeks ago, and the truck acts the same regardless of which tank it is running on. That does not rule out a clogged filter (new one gets installed on Saturday) or a fuel pressure regulator issue. (I doubt there is an issue with the FPR because I have no extended crank or signs of an excessively rich mixture.) I don't suspect an EGR issue, it acts the same with the vacuum line to the EGR connected and without. I can manipulate the EGR open with my fingers and the engine stumbles, so I think the EGR is closing fully and not hanging open.


Thanks for the input gentlemen!!!
 
Install the knock sensor with torque wrench to setting... I forget... but do not overtighten.

There's actually 2 EST modules from factory. One takes away a couple degrees at around 3500 RPM and one adds a few degrees. Since then there is only one replacement. Point is the spark latency programmed into chip/bin is proper for factory sensor.

Before you take off the Accell cap, shake it and see if it wiggles? Some do not seat well and even tight is not on properly? Seems the line up pins are bigger then the line up holes? After that is fixed or at least checked it is a good cap and rotor.

Usually if the spring holding button down is broke, which happens way before the cap and rotor wear out. You will see black dust looking arcing all over rotor first, thencan also see it in cap.

Problem with fuel pressure is hardly ever to much! The symtoms you have are indicative of the normal problem of to little pressure. Even at 12-13 there is barely enough fuel to run a stock engine.
 
Got very little done in relation to this Saturday. Ignition module and plugs are still in the mail. But I did get the trailer hitch installed and the wiring buttoned up. Also got the new fuel filter installed, and replaced a fuel line. Module and plugs should be in tomorrow. Also in farting around with the truck the other day, I noticed the alternator falls on it's face and doesn't put out once it gets warm, so after digging around on here I'm doing the Pontiac Trans Sport van 140 swap.
 
EFI really likes steady voltage... :whistle:


I am aware. Light bulb went on about that when I laid my DVOM across the battery. But at the same time, I don't think that's related to my drive-ability issue.
 
Yes it does! Low voltage goes all the way to what fuel pump is putting out, lower volts = lower pressure = lower volume = not enough fuel and your hesitation issues...

Plus lower voltage effect injectors the same way...
 
Yes it does! Low voltage goes all the way to what fuel pump is putting out, lower volts = lower pressure = lower volume = not enough fuel and your hesitation issues...

Plus lower voltage effect injectors the same way...

I don't think they are related. High beams on, heater fan on high, cooling fan on, and rolling down three windows at once has no effect on how the truck runs.
 
OK! But what I said about voltage still stands...

Lots of these issues I can find with data logs! If more guys would just buy a $45 cable to hook to their laptop I could diagnose them all!

Here's a starter Tutorial for TunerPro RT. Only a small portion of it is needed for just data logging.
http://coloradok5.com/forums/showthread.php?t=302680
 
OK, last week Monday the plugs and module came. I installed them in the truck, no change. Wednesday I tore into it by continuing with on with the flowchart for the code 42. As directed I was searching the tan with black trace wire for a short to ground. Ripped the better part of the whole underhood harness apart and didn't find anything to speak of (a few things I repaired, but not related to the EST circuit.) Pulled the wiring from the ECM out through the firewall. Found three ****ed up wires (including the EST wire) that were between the firewall and the ECM. I think they got damaged by getting caught up the cable/arm for the heater. Fixed the wires, no more CEL and the truck runs great, but I haven't gotten a chance to really drive it.
Today I drove it to work. Lots of power and no hiccups!


I gotta go through and tidy up the underhood harness. ALL of the convoluted tubing is gone. I found one here and I may just drop the coin on it and replace the whole thing.
 
So, tip of the day: when you gotta check a wire; you gotta check the wire!







 
Dam those are hard to find! Usually takes OHMing the wire from both ends to even see if there is an issue in the middle.

Really good work! :waytogo:
 
Yeah, I learned a while back on a streetsweeper where come convoluted tubing wore through a 10ga wire where the loom was ziptied to something. "Oh that loom looks fine" doesnt cut it. You gotta physicaly see every inch of that wire, end to end. That's the only way to know it giant compromised. A continuity test will only tell you that it ISN'T completely broke. I think the est wire would have ohm'd out fine, and it very possibly could have not showed any continuity to ground with the truck just sitting in the driveway.


Drove the truck to work again today and I am super happy with how it performs. The list of repairs it needs is getting shorter and shorter all the time, and it seem like the repairs I've been doing lately have been huge "quality of life" type improvements. Feels good man.
 
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