Rattling like a vaslve rattle--if so need to pull valve covers and check the rockers,push rods ,basically the valve train
SOURCE: 1996 Crown Vic, Valve noise under heavy acceleration
No use what's in there, but have the engine de-carboned by a Ford dealer, or remove the octane adjust shorting bar located near the ignition module (retards timing 2 degrees), this will in most cases cure the issue unless there is allot of carbon in the cylinders. There are also methods of ing this de-carbon procedure at home, check on the internet for tips.
PLEASE RATE THIS SOLUTION
SOURCE: Flat spot around 2000r/m
Try accelerating at different speeds, for example push pedal further down, or ease into it real slow & let it climb, and see if it still dies at 2000 rpm, just to see if pedal position makes any difference to see if maybe TP sensor has bad spot.
SOURCE: Exhaust pipe rattles when car idles. Had muffler
Check the heat shield on the Catalytic Converter, after a few years they start to rust off and rattle. Crawl under the Pathfinder and bang along the Converter and muffler area and see where it's coming from.
Good chances are, it's from the heat shield since you already had everything changed from the Cat back.
Good luck and hope this helps.
SOURCE: How do I replace an egr valve on my 2000 Nissan
When you pop open the hood, look at the side of the engine on your right (driver's side). Underneath all the air intake duct that connects to your air filter is the EGR valve. It may have a grey plastic top with an electrical connector attached to it (this top is about an inch and a half to two inches in diameter), a middle section below this that is made from a silvery metal with two rubber hoses plugged into it, and below this a bottom section with a metal pipe maybe three quarters of an inch in diameter connected to it. The metal pipe curves around and goes back behind the engine. There are two bolts that the valve is mounted on. To remove the valve, first you have to get a bunch of hoses and stuff out of the way to expose it, then disconnect the hoses and electrical connector from the valve, then disconnect the metal pipe connected to the base, then remove the two nuts on the two bolts. There is a gasket between the EGR valve and the engine which you will have to replace. It cost less than two dollars, good luck and hope this helps. WHen installing just do everything on revers. If you not sure if you can recall how the hoses goes back, take picture with your cell phone as reference.
FRONT Of car IS HERE X
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