Carbon buildup along the firewall?

Tiny
RYDER1477
  • MEMBER
  • 2004 CHEVROLET IMPALA
  • 3.8L
  • V6
  • 2WD
  • AUTOMATIC
  • 285,000 MILES
So a month ago I had to limp back to home approximately 200kms, because my car had massive power loss and was suddenly super loud. I thought it was a head gasket, but it wasn't.

I replaced the catalytic converter, and I thought that my problem could've been the not so tight exhaust manifold bolts when I uninstalled the old one.
But it wasn't.

It's still loud, still doesn't idle right, hesitates when you give it gas and is still just as loud as it was before.

But now, there is a lot of carbon buildup along the firewall and anything under the fuel injectors.

See images

I don't quite no what to make of it but I need this car for once to just run normally.
Also, I ran the OBD and got the same 2 codes back that I've had forever.

P0122: H02 HEATER CONTROL CIRCUIT BANK 1 SENSOR 2
P0036: THROTTLE/ PEDAL POSITION SENSOR SWITCH A CIRCUIT LOW

I've replaced the throttle position sensor 2x and the downstream HO2 sensor.
Never changes or fixes anything.

Could it be the crankshaft position sensor or the camshaft position sensor?
And I found the other end of a plug that had no connecting wire. What goes there?
Saturday, June 7th, 2025 AT 2:20 PM

9 Replies

Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 51,615 POSTS
Can you tell me the color of the wires to the connector? That way I can look it up and see where it goes. Can you upload a short video of the noise so I can hear it? You might have an EGR tube or valve that is having an issue. Check out the images (below). Please upload pictures or videos in your response. Use a flashlight to inspect.
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Sunday, June 8th, 2025 AT 12:27 PM
Tiny
RYDER1477
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I can't get you a sound sample cause I unhooked the throttle body and am waiting on a new TPS and idle air sensor. The wires are 2 black and 1 red. . See image below
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Monday, June 9th, 2025 AT 1:35 PM
Tiny
KEN L
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The connector in the first post has two wires?
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Monday, June 9th, 2025 AT 4:38 PM
Tiny
RYDER1477
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  • 43 POSTS
Yes. But I untwisted the 2 black wires. They were taped and when I unravelled it, the 2 black wires were twisted together. NOt sure if that helps but ya that is odd, which would only make another open ended wire with no connector.
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Monday, June 9th, 2025 AT 5:21 PM
Tiny
KEN L
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Gotcha, it looks like that wiring goes to the wiper washer fluid pump. Did you get a chance to see if the EGR was making the noise and making it run poorly?
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Tuesday, June 10th, 2025 AT 11:41 AM
Tiny
RYDER1477
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  • 43 POSTS
Yes, I took it apart, cleaned the tubes for it and installed it again but during that task I saw a piece of gasket sticking out of the flange that connects the front exhaust header to the back. Just below the EGR actually, I suspect that that is probably the cause of the excessive noise and sound.
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Thursday, June 12th, 2025 AT 1:58 AM
Tiny
KEN L
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Yep, good find. That should take care of the noise.
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Thursday, June 12th, 2025 AT 8:38 AM
Tiny
RYDER1477
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How would I go about fixing that? Basically taking off everything around it, above it. It looks like quite an extensive repair, Is it?
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Thursday, June 12th, 2025 AT 9:57 PM
Tiny
KEN L
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You may need to remove some parts to get to the EGR tube or valve, it should not take more than 2 hours at a shop. Please upload pictures or videos in your response so I can see what you are talking about.
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Friday, June 13th, 2025 AT 10:58 AM

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