Hi, after nearly four years of trouble free operation, my 91 TBI Bird needs help. Was cruising to work on the freeway one day, doing around 80 and suddenly the car lost power, started chugging and bucking.

Miles from my regular mechanic, I went to another shop, asked them to put the car on the diagnostic computer. Instead they changed the intake manifold gasket, drilled holes ahead of the cat, and changed the coolant temp sensor, said my engine codes showed a bad O2 sensor, then charged me 300 bucks. What a hoax.

Car still didn't run right, so I changed the fuel filter, spark plugs, TPS, O2 sensor, and got the most badass 3" mandrel bent system from Rich's Performance Muffler in Oceanside, holy crap it rocks! Header style y-pipe, high flow cat, and stainless steel Magnaflow catback. All that really helped, obviously I needed that stuff.

Ran better, still hiccupping at low speeds though, drove it home, took it to my regular mechanic, and he checked engine codes for real (I got code 44 with the paper clip trick, running lean). EGR problem came up on the scanner.

Mechanic said EGR was most likely sticking, causing lean condition, so the ECM was dumping in more gas to compensate, causing low speed driveability problems. So I'm going to try changing the EGR and see what happens. My mechanic was too busy to spend any more time on it today, plus he didn't charge me anything for putting it on the scanner, so hopefully this will take care of the problem. Will post pics of the exhaust soon, it is a thing of beauty--dual round polished K&N tips, super nice.

 

Took the EGR off, cleaned it per an online article I found, lubed it, put gasket seal on the gasket and refitted. Car runs much better. Will replace it next week. Noticed when working the throttle, the EGR was very slow to respond (plunger goes up and down) and seemed kind of sticky still. Even so, I've got my power back, and the Magnaflow system rocks!

Going to Coachella for the weekend, will put the new EGR on next week. Car runs sooooo nice now with all the new parts on it, and who knew a good exhaust could make so much difference? Revs higher and shifts are much smoother. I love these cars.

 

Okay, the problem is intermittent--a new part will seem to help, then we are sucking air again. Taking it to a good mechanic next week! Any ideas? Any guesses? Help, I've got Code 44, and my exhaust smells strange! Now I'm thinking it's either MAP sensor or EGR related, ECM problem, or a a fuel pressure issue...any ideas would help. Trickster where are you? : )

 

Fuel pump!!! I had a couple of other issues too, but the real culprit was a perforated rubber hose at the top of the fuel pump. Gas was being pumped back into the gas tank, instead of to the motor. Use injector cleaner, and Techron sparingly, I have the feeling that stuff ate the rubber hose, plus it was just old. There is now a brand new pump in the tank, and the car hauls *** like never before!

And I have a custom made 3" Magnaflow system now too, will post pics later. New Accel cap and rotor, and I replaced all sensors, fuel filter and the spark plugs etc. The first time I drove it, I did a couple of huge burnouts without even trying. The car performs even better than when I got it, so I'm glad this repair was needed.

"On the road again, it feels so good to be on the road again..." Willie Nelson

 

A lot of people overlook a bad fuel pump/hose. I had a similar prob awhile back. The car would start fine cold but not start at all when the engine was hot. The prob was a tear in the fuel pump hose that would expand after the fuel pump started running. That explained the filure to start up hot. Furthermore, there is no easy way to check fuel pressure on a stock TBI system, you have do disconnect the fuel line.