I have been dealing with some similar issues but I’ve finally had a bit of luck resolving it so I figured I’d share. About 1,200 miles or so ago I was due for my 75,000 mile service (which I did myself) which includes spark plugs. Since I was doing the plugs I also decided to change out all of my coil packs and go Stage 1 EPL tune at the same time (why not right?). Even with everything stock I had been feeling stutters and logging misfires since I got the car about a year ago. So I figured now was the time to get it all done.
So I went with Bosch plugs (IKH24) and gapped them at .024 but admittedly I did not take the time I should have nor did I have the best gap tool at the time so I think they ended up varying between.024 and .026. In any case, in went the plugs and coil packs
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and everything was running much smoother than before. A couple days later I received the stage 1 tune and flashed the car. Went for a drive and almost immediately started with some pretty bad misfires which were audible along with the sputters at low RPM. After the first 100 miles I had quite a few misfires.
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I did let the car adapt for about a week and put 1000 miles on it and it was strong but still missing sporadically at low RPM. Then when I was pulling away from a stop at about 3/4 throttle I got the flashing CEL along with more audible misfires so I checked my OBDEleven and had 3 hard misfires
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The day after that I had another in cylinder 4 that was static and would not clear and was causing some nasty vibration at highway speeds.
Time to get this fixed.
I flashed the car back to stock and cleared all the DTCs then drove for about 10 miles and checked the misfire count. Cylinder 4 was definitely a problem.
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Bought another set of all new plugs (this time NGK) and some proper gapping tools and took my time gapping them. But this time I gapped them down to .022 instead of the .024 some are recommending. With the added boost and air density of the stage 1, I don’t think .024-.026 is tight enough. Removed the old plugs and sure enough cylinder 4 insulator was smoked.
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Put everything back together and re-flashed the stage 1 tune. Took it for a spin and WOW! No more sputter, steady low end power, no audible misfires and the oil temp actually showed a couple degrees cooler while driving around. I let it fully warm up and gave her a few WOT runs and the power is smooth and strong. No more hesitation or sputters. This car has never been this smooth since I got it even when bone stock. Got home and checked the log....
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Perfect!
I know these cars have a lot of smarts and self adjustment in the engine, but I’m pretty convinced that some of these misfire issues may be caused by basic plug gaps that are too big for the amount of boost being generated. I know with a smaller gap you might get a slightly lesser combustion and possibly a little less power, but I’ll take the smooth low end power, no sputters and no fried plugs over that any day.
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