Which MagnaFlow did you go with?

I think its the lower cat because I heard something rattling on the trip up to Portland.

Everet <img src="/forums/images/graemlins/patriot.gif" alt="" /> <img src="/forums/images/graemlins/cheers.gif" alt="" /> <img src="/forums/images/graemlins/kewl.gif" alt="" />

hey Everet,

thats 1 thing I don't miss about Cal. it's smog checks, don't think I would every by-pass a cat. there, so did Kelly PM you back ? I was chatting with her before dinner. she did a little things on her truck seems to be working ok. I am a little worried on the age that could be on the W/P and T/B and tensioners.

does it cut out at 3000 or what does it do mine turned out to be bad plug wires

Had a similar scenario with my '01. The timing belt had skipped a tooth or two on one of the cams. Don't know if the '96 models had the same trouble codes available as mine, but the garage pulled a cam timing code out of it when this happened (bought a code reader after that, it has paid for itself 10x over by now). Don't know why I'm posting this, as it's likely an exhaust issue, but the thread title reminded me of that incident.If all else fails - try the cam timing.
Good luck.

Yo Everet - What was the outcome/solution for your power problems discussed in this thread?

I'm having very similar issues with my '97, though I can rev the engine to 2K or higher and it seems to run smoother (parked in the driveway). It stalls at idle when cold, but will rough idle when warmed up, with random pops from the exhaust or intake. I still get error codes at the higher RPMs. Here are the codes I'm getting: the misfire codes on all cylinders, the internal RAM error and the knock sensor value range error.

I've gone through the ground points and can't find anything obviously wrong. I have good voltage on pin 26 of the ECM harness (ECM power) and good continuity on the ECM ground (harness to chassis ground point). I haven't checked the timing yet. And as I noted in my dual battery thread, I did short a hot lead tied to the starting circuit (ECM side) for a millisecond, the problems beginning on the following start up. So it could be the ECM (I bought one on eBay and will receive it by this coming weekend). But I've found lots of posts on the various Kia forums reporting the same group of error codes and the ECM wasn't the problem (though most didn't report the solution).

Anyway, I'm stumped. Any thoughts???

It was both cats! The next problem was O2 sensors were both bad. Had to run new wires from lower O2 sensor to computer.
Cleared computer and it has been fine since.
Hope this helps!
Everet <img src="/forums/images/graemlins/patriot.gif" alt="" /> <img src="/forums/images/graemlins/cheers.gif" alt="" /> <img src="/forums/images/graemlins/kewl.gif" alt="" />

Thanks for responding so quickly! I went out and double-checked the ground points by running a lead to the battery and measuring the voltage at each ground, to include any bare unions of multiple ground wires. Everything read a steady 12.8 volts (and that's with the battery in the back of the bus! <img src="/forums/images/graemlins/kewl.gif" alt="" />). I also reworked the intake manifold-to-chassis and battery ground-to-chassis connections. They are all fresh, 4 gauge wire now. And that didn't fix the problem...

I'm hoping it's a problem with the cat. I've been dying to replace the exhaust from the cat back. But the muffler shop won't touch the cat unless it's bad (gotta love living in Cali! <img src="/forums/images/graemlins/rolleyes.gif" alt="" />). And fresh pipe on a dirty cat is like putting lipstick on a pig (man, I hope Hillary Clinton doesn't troll this forum <img src="/forums/images/graemlins/scared.gif" alt="" />). The problem is that I don't think it will run well-enough to get it to the muffler-guy. I guess I could have it towed... <img src="/forums/images/graemlins/baby.gif" alt="" />

If it's the timing belt, that's going to be a major pain! <img src="/forums/images/graemlins/zombie.gif" alt="" />

I'll keep you posted on the status. Thanks again for the info... <img src="/forums/images/graemlins/patriot.gif" alt="" />

The replacement ECM arrived today. So I "dodeca-checked" all of the wiring under the driver's side dash, the passenger floor board & ECM harness, to include ground points, and even poked a look at the cam position sensor and O2 sensors (didn't remove, just checked wires for integrity). Then, with batteries disconnected, I swapped out the ECM. It started without stalling, but would bog down when I touched the throttle. I think that was partly-due to the ECM testing the system and adjusting. The engine "loped" a bit at first, but seemed to smooth out after having some run-time. I kept checking and clearing the pending codes. The first set was the same: misfires and internal RAM error. But it was running. So I had a feeling that the old ECM was part of the problem. But it isn't the only problem.

Once the engine smoothed out and responded to the throttle without bogging, I took it for a test-drive and checked/cleared the pending codes a few times. The first codes were misfires, but no RAM error. A few minutes later, the engine felt gutless - more so than I have experienced before. I checked for codes and found P0171: system too lean, but no misfires or RAM error. I have been getting the P0171 code off and on for the past year. It could be a leak in the intake behind the MAF (first appeared after I changed plugs, coils and wires). But I'm also wondering if it could be a bad O2 sensor... maybe both? Anyway, the engine idle immediately-returned to a "minor lope" when the code cleared. And the engine was much more responsive. So I'm wondering if the "system lean" error is causing the ECM to make the engine run too rich. Possible?

That noted, here's my plan of attack...

- I'm going to pull the throttle body and reseal everything that was removed when I did the tune up. I'm also going to remove the Spectre air filter (cone-type) that I installed at the same time I did the tune up (it came with the vehicle, but was removed by the previous owner so the vehicle would pass smog). I'll re-install the factory air box with K&N filter (that's how it was running prior to the tune up, which was not a problem).

- If I'm still getting the lean-code after, I'm going to take to a muffler shop and have the exhaust checked, to include the O2 sensors, if they can do it.

That's where I'm at right now - not 100%. But it runs!!! <img src="/forums/images/graemlins/kewl.gif" alt="" />

I started pulling the intake system apart this afternoon. And it didn't take long to find a leak behind the MAF sensor. In fact, it was the rubber hose between the MAF tube and the pipe to the throttle body. The rubber was dry rotted and the hose was splitting between the corrugations. There were at least 4 gaping holes that I could stick my fingers through. I think part of the problem is due to the body lift - the filter box has been lifted a few inches higher, but the engine hasn't. It seems the extra stretch on the old rubber was just too much. So I'm looking for a flexible hose to replace it... one that will fit without strain.

The problem for me is, living in California, any part of the air intake or emissions system that isn't designed for a vehicle (i.e. isn't OEM-spec) isn't legal. The vehicle won't pass the smog inspection. Only aftermarket parts that are California Air Resource Board (CARB) certified are legal. K&N makes some cold air intakes that are CARB certified. But I don't know which, if any, will fit the Sportage. And since they sell for $250 USD, I'm not interested in going that route. I think I've found a potential solution using silicone intake tubes.. I'm going to measure the spacing and angles between the MAF and TB pipe tomorrow and see if I can find a combination of elbows that will do the job. Then I'll work on finding an OEM hose to install once every 2 years, when my smog test is due... <img src="/forums/images/graemlins/nana.gif" alt="" /> <img src="/forums/images/graemlins/notooth.gif" alt="" />

I had the same problem with my OEM intake splitting without a body lift. My fix was to wrap it like a mummy with electrical tape. Been working fine ever since. <img src="/forums/images/graemlins/lol.gif" alt="" />