1998 Forester L 5 spd 2.5l had the chk eng light on. Next thing I knew the egr vaccuum modulator literally melted on the bottom that connects off the manifold. Replaced both o2 sensors, pulled egr valve off and cleaned it(it was dirty), checked vaccuum and replaced modulator. Chk engine light went out, all was fine, but when engine heated up, it melted the bottom of the modulator again! Chk eng light back on! The car would not go over 3 miles an hour. I haven't been able to get it for a new code reading. The car ran great until it warmed up.
I am going to replace the egr valve since I've read but that could cause the 'hot' gas to enter the modulator and cook it? Also I can't get the car to a shop because I live so far away and a tow would cost me mega $$$
Any suggestions?
FWIW,
I finally nailed it down to the catalytic converter that was plugged. The back pressure from the clogged cat was the culprit that caused the melting of the back pressure transducer.
After getting the codes read, I also replaced the knock senser. I ended having the following codes;p0400, p0303, po304, and po325.
A tip for those(like me) who didn't know; Autozone will loan you an obd code reader with a small returnable deposit. Had I known, I could have had this car up and running alot sooner.
Good luck to all
Prior to the transducer problem that was a result of the bad converter, I had had the code read and it read p0325 all along.(knock senser). I replaced the o2 sensers as a maintanance issue. The car had NO power!
As a matter of back tracking the problems through replacing the egr components, I ultimately removed the frt o2 senser and the car had power again. This pointed to the frt converter... and yes it was plugged!
I have since educated myself about the OBD codes. I think there is an OBD code (p04200) that refers to catalytic converter problems. I don't know if this code ever appeared because I repaired the problem before I could get a read on it.
I wasted alot of time and money replacing the egr components when if I had bothered to get a obd reader, I could have made things easier. Autozone is great and if you can't get your car there, at least you can 'borrow' a reader.
What you did by removing the 02 sensor and driving the car with it removed is the first step in diagnosing a restrictted converter! I've seen many egr modulators meltted because of restrictted exhaust but generally po420 doesn't point to a restrictted conveter or exhaust system. A regular old vaccum gauge or a fancy backpressure gauge would pinpoint the restriction. Po420 often means the converter isn't operating at the correct temperature which doesn't necessarily it's restrictted. It's unlikely that the borrowed code reader from the zone would have pointted you to the converter without the po420 code but a vaccum gauge and a haynes manual would likely have!
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