Question about 2003 Chevrolet Monte Carlo

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Power loss i have a 2003 chevy monte carlo with 87,000 miles my car idles great but when i press the gas hard the engine revvs but there is power loss the tranny shifts fine (service eng soon) had it scanned trouble code (p0404)fault in egr position sensor (probable causes) 1failed egr position sensor 2open or short cirtuit condition 3failed egr valve 4failed egr position pressure sensor where applicable 5failed egr position sensor where applicable (question) can a catalytic converter set a egr code?

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  • shawnmyron May 25, 2009

    I (shawnmyron) had my catalytic converter replaced and it fixed the problem. It is true that a clogged catalytic converter can trigger an egr code (P0404). The service engine light is gone. Thanks to everyone who posted problems, troubleshoots, and solutions.

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  • Chevrolet Master
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Can't answer your last question but catalytic convertors that are just not working anymore won't cause any loss of power. However, if they have shattered inside (they are kind of a ceramic honeycomb) they can dump junk into the exhaust system that can eventually clog your muffler or resonator.
Checking whether this has happened isn't difficult; after the warm up of the engine, either you or a helper needs to listen to the exhaust note. If firing of the cylinders is still distinct, the system isn't clogged with shrapnel; if it seems to hiss at higher RPMs, it is likely clogged.
This effect is easy to miss; I've had two failures and when cold, the engine would pull fine because the chunks of ceramic would fall to the bottom of the muffler and glue together somewhat. Once hot and agitated, they would clog the muffler and cause a severe loss of power but the idle would be OK. A hill that I would normally pull at 70 MPH, I couldn't top at all; had to sit and wait for things to cool down before proceeding.
It also seems some engines appreciate a bit of back-pressure in the exhaust system because the car gained in mileage and pulling power for several thousand miles before the clog became critical causing the mileage to fall sharply along with the power.  

Posted on May 23, 2009

  • Steve Allison
    Steve Allison May 25, 2009

    Thank you too - posting back the resolution of your problem may help others.

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  • Chevrolet Master
  • 2,359 Answers

An EGR valve leak can cause loose of power at 1,500+ rpm.

Carbon built-up on the back of the EGR and the EGR passage tube is the main cause of the problem.

====

Check for

vacuum leaks on intake manifold,

the air tube between the air filter.

intake manifold vacuum hose.

===
clean throttle plate with Berryman carburator cleaner

SEE sample picture HERE
===

Also remove carbon built up behind the EGR valve and the EGR passage tube.

===

Vacuum leak WILL offset the intended 14.7 to 1 air fuel ratio.

More un-metered air (leaks) will lean out the fuel mixture.

Use small amount of Berryman carb clearer at potential air leak area will help you identify trouble spot.

At idle,just spray and listen for the RPM surge.

The in-rush of carb clearer will increase the RPM on the motor.

Record the problem spot(s) and address it later.

===

EGR carbon built up require 2+ hours to clean from start to finish.

You will need a new EGR base gasket before your start.

Locate and remove the EGR valve after the vehicle is cool down.

Carefully record the connector and vacuum line (for older vehicle) location by drawing an easily to follow diagram.

Remove the EGR valve.

Inspect the location of the carbon built-up inside the valve and the EGR passage tube.

SOAK these areas with WD-40 spary.

You will need a small screwdriver,cloth hanger and lot of newspaper and time to get this cleaning done right.

RE-SOAK the carbon and let it sit for over-night will also help.

One the last round,pass a shop vacuum of the EGR valve and the passage pipe.

Install the new EGR gasket and connectors.

Allow the vehicle to warm up outdoor to burn up any remaining WD-40.


Take it for a test drive.


Please rate my answer if it's useful to you.


Cheers,

Mustgo

Posted on Dec 19, 2009

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