Gunpowder burning smell when accelerating

[jp199]

Hi guys first post here. This is gonna be a long one so I'll try to lay everything out as simply as possible.

I have a '88 Samurai with a '93 Sidekick 1.6L 16V with manual transmission swapped in. I'm in California, so everything is compliant with smog. It has a new muffler and piping, but not sure if the cat was replaced when that was installed. I noticed a gunpowder like burning smell when i accelerate heavily. I had CEL code 51 for EGR and found that my fuel injector pressure damper was leaking and the fuel was dripping on the EGR temp probe causing an incorrect reading and throwing the CEL. I'm assuming this put the car in limphome mode and caused it to run rich (thus the smell). However, I've replaced the pressure damper and there is no more fuel leak. The CEL is off and has not come back on for a week of daily driving. But the smell is still there!

I've heard some say that the gunpowder smell can be mistaken for clutch slip. I recently had the rear wheels off the ground and started the car. even in neutral the rear wheels were spinning slightly. Not sure if that is helpful info.

The smell has been around for a while, so maybe it was long enough for the cat to get clogged up, but it doesnt quite have the sulfur smell of a bad cat. Really at a loss here. 

Thanks for any ideas!

[fixkick]

Hi guys first post here. This is gonna be a long one so I'll try to lay everything out as simply as possible.

I have a '88 Samurai with a '93 Sidekick 1.6L 16V with manual transmission swapped in. I'm in California, so everything is compliant with smog. It has a new muffler and piping, but not sure if the cat was replaced when that was installed. I noticed a gunpowder like burning smell when i accelerate heavily. I had CEL code 51 for EGR and found that my fuel injector pressure damper was leaking and the fuel was dripping on the EGR temp probe causing an incorrect reading and throwing the CEL. I'm assuming this put the car in limphome mode and caused it to run rich (thus the smell). However, I've replaced the pressure damper and there is no more fuel leak. The CEL is off and has not come back on for a week of daily driving. But the smell is still there!

I've heard some say that the gunpowder smell can be mistaken for clutch slip. I recently had the rear wheels off the ground and started the car. even in neutral the rear wheels were spinning slightly. Not sure if that is helpful info.

The smell has been around for a while, so maybe it was long enough for the cat to get clogged up, but it doesnt quite have the sulfur smell of a bad cat. Really at a loss here. 

Thanks for any ideas!

well I can not know the source of any smell.
is the cars top off,? or windows open during this smell.
the cat if overheats makes smells that is for sure.
good thing no fire with that nasty gas leak. wow.  dripping on  very hot EGR main.
if the EGRt (thermo sensor fails) that  does not stop EGR from working it only detects the valve opening and getting hot. and if not hot 51 DTC sets.

the real question is the smell from
1: the exhaust tip.?
2: the casing sides of the cat due to red not running, if rich AFR it will get hot. and all CATS rich, stink,.
3: or that fuel got on things there (grease?) or what not, that is now stinking.


if the clutch slips you'd know that driving. and will get worse fast, for sure free play set wrong.
with the transmission in neutral the prop shaft can spin gently,  just from GL4  lube in the box.  cluster gear to main shaft lube friction. but is weak this action.
the clutch pressed down must make the box go dead, but you never said where the clutch pedal was , rear tires off the road.?

if the engine is getting 26-28mpg, then cat is happy, is it?  and drive it to get the cat baked dry now. (from any limphome)
not aware me of code 51 causing limp.   but Calif has there own ECU and own EGR setup matched, non FED car, non FED ECU.

but yes the ECU on these cars can get lost, no DTC at all. easy. like:

AFR way off (air fuel ratio)
leaking injectors.
misfiring for any reasons
causes CAT to get hot, and stink in fact that is it purpose that to stink (the conversion of HC to , water, CO and CO2 and other sinks)


good luck to you and Cheers !