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Re: Someone Please Help!
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Posted by ARi [Email] (#2847) [Profile/Gallery] (more from ARi) on Mon, 30 Apr 2001 13:10:48 Share Post by Email
In Reply to: Someone Please Help!, MattC, Sun, 29 Apr 2001 01:57:24
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When did the mechanic replace the plugs? How old are they?

OK, there are a bunch of possiblities - first off, if the spark plug gap is too big, you'll get misfiring when the boost comes up. Make sure that the spark plugs are the NGK's specified in the manual, and that they are gapped to the specification in the manual. NO SUBSTITUIONS ACCEPTED! And have the gap checked - plugs don't come out of the box properly gapped for all cars.

Yes, it can be a sign of a bad DI (Direct Ignition) cassette. They cost around $300 in parts to replace. That's why you want to check the spark plugs first - much cheaper.

As a check of the DI cassette, unbolt it and pull it off the spark plugs. Then flip it over, so you've got four posts sticking up in the air. You'll see it's a plastic cover held on with a few torx screws. Undo the screws, and lift off the plastic cover. Under it you'll see a circuit board and four whitish plastic tubes - these are the individual spark coils. Peering in, you should see oil in the tubes, almost full. If any of the tubes is leaking oil, or a tube (or two) doesn't have any oil, you need to replace the DI. A DI can still be bad and have all its oil, but if any of the coils is leaking oil, you have a bad DI.

Lastly, 2000-3000 rpm in 2nd or 3rd in an Aero is serious boost territory. How high is the boost gauge going when this happens? Is it going well into the red? There is a safety system in the engine control that will shut off fuel flow if the boost goes too high - and the result is pretty dramatic - it almost throws you against the windshield. This cutoff could be happening to you if the boost is going high. It could be one of two reasons - either the shut off switch is kicking in a too low a boost pressure, or there is some other problem in the car that's causing the boost to go too high, and your safety system is kicking in. If the boost is going well into the red, have your mechanic check the plumbing to the wastegate actuator, and that the linkage from the wastegate actuator is connected to the wastegate properly and moving OK.
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