Onward Troubleshooting Progress for Karlino

So in case you haven’t noticed, I’ve not blogged here for almost 2 weeks.  I’ve been very preoccupied about trying to get Karlino repaired, to be able to start up again.  I’ll have to admit it’s made me a little depressed.  And carpooling with my wife daily has added to the stress.  I feel like I’m in a mechanic’s wormhole hell…

Is there escape from this mechanical quandry?

Anyway, I’ve been trying to diagnose/fix my car’s non-starting problem since Monday afternoon, the 22nd of February.  Thus far, this is what I’ve done:

  • checked CEL codes…got 2
  • P0402 EGR Flow Excessive & P1345 Manufacturer Control Ignition System or Misfire
  • took apart & cleaned out the intake manifold, specifically that little hole that tends to get clogged up
  • replaced the plugs & wires with new NGK parts (verified I got spark, on all cylinders)
  • after trying to unsuccessfully start it (again), I was told that the raw gas (which I did smell from the exhaust pipe) could foul the new plugs
  • therefore, I dutifully cleaned & dried the plugs with carb cleaner & canned air
  • replaced the camshaft position sensor (made sure I disconnected the negative battery cable first)
  • verified that the timing belt has not broken or slipped any teeth

Putting all back together, with anti-seize compound & properly torqued, the motor does turn over, but does not catch fire.  I have verified that I can hear the faint whirr of the fuel pump. I have tested all the fuses with my multimeter.  So with gas & spark seemingly available, is it mechanical or more electrical (& I cleared the CEL codes & none have reappeared recently)?

I’m only down to a few things that I (& various driveway mechanic friends of mine) can think of:

  • possible a faulty coil pack(s) – but I do get spark
  • faulty and/or not synched crank position sensor
  • some other sensor?
  • faulty firing of injectors

So, there you have it.  Racing Ready is now tempted to take it to the dealer, or a shop, but there’s got to be a simple solution.  Others will say, “Enough already!”  But the budget says otherwise…hmmm…


P.S. – I don’t understand, I must not be feeding the right supplements to Karlino.  Today makes two 12mm 3/8″ sockets that he’s ingested into the black hole of his front bumper cavity.  I will need to do some magnetic dentistry & work on his diet.  Maybe it’s that he’s anxious to get all properly lubricated with his pending AMSOIL fluids (for engine, tranny & rear diff).  Those will come only after we get Karlino running again!

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5 thoughts on “Onward Troubleshooting Progress for Karlino”

  1. Dan, have you verified that the spark plug wiring was replaced in the correct order? I had my plug wires backwards one time and got the exact result you are speaking of. I was firing 3, but fueling 4, then firing 4 and fueling 1 etc.I have a little free time in the morning if you are working on it. I’m sure you know what you are doing, but just in case… http://www.miata.net/garage/ignition.html#wires

    I always know exactly what I am doing, then re-do it correctly when it doesn’t work.

  2. OH! and try firing it at night to see if your coil pack is arcing to the block. I had this happen a few times as well. I would not get enough spark to the plugs to fire. Just pop the hood and have the Mrs. turn it over a few times while you watch the coil pack. Be sure to do this in the dark. If you see blue sparks at the coil pack, then you’ve got a pinhole in your coil pack.

  3. Remove the egr valve and plug holes try to start
    the 402 sugests that the valve is haging open posably controll probably valve somewhat comin fault
    miss fire code would have been set when it was idling and the valve was open partaly.
    dose it kick at all or just wheel over?
    dose it have injector pules?


  4. It is also common for the vac port in the intake for the egr/boost sensor gets pluged up -check compleat line for restriction

    wont cause nostart but will give egr codes

  5. Dan, I didn’t see this posted in the blog itself, but have you actually removed the EGR valve itself and tried cleaning it?
    There is always the possibility that the vale itself is bad.

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