Date:         Sat, 9 Feb 2008 02:46:46 -0500
Reply-To:     Dennis Haynes <d23haynes57@HOTMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Dennis Haynes <d23haynes57@HOTMAIL.COM>
Subject:      Re: SMOG TEST failure
Comments: To: john@UCSB.EDU
In-Reply-To:  <47ACB68B.90209@ucsb.edu>
Content-Type: text/plain; format=flowed

The first failure clearly shows an engine running problem and a margianl O2
sensor or sensor control.
The new catalyst cleaned it up but since you didn't correct the real
problem, you destroyed the new one. The new cat with a properly running
engine should have given near readings for both CO and HC. The fact you
still had these pollutants coming out was a sign the cat was over worked.
The current readings as I said are showing good overall mixture control but
he high HC is still there.

The Emicco Cat is probaly the best after market unit out here for the VW. It
looks and has the same outer dimensions as OEM and the area of the media
face is almost the same. The depth of the media though is only about 1/2.
This offers less contact time and as the cat fails, less oppurtunity for
cleaning the exhaust. Since the repalcment cat failed in less than 5
years/50,000 miles it is supposed to be "reported". New cats will usually
have a card to fill out for this. You can ask the supplier if they can get a
replacement but I doubt it. It obviously did work when first installed.

It is normal for engnes to have higher CO and HC levels at idle that at
speed. Mixture realted mis fires, cylinder balance, vlave and ring problems
and igniton timiing are more of a problem at low speed high vacuum engine
operation. The Vanagon suffers more as the pollution control equipment is
minimal. There is no air pump, exhaust after burners, etc to help. There is
also no EGR to help with the NOx emissions under load. They really relied on
things being "right" in order for it to work.

For all of California's reputation for emissions standards, they are really
lax for our vehicles. here 2wd have to get the Dyno test which will test the
cat no matter what, (NOx reduction). Sysncros are still allowed the idle
only test the limits for anything 1981 and newer is 1.2%CO and 120 ppm HC.
As bad as that sounds a properly running engine will do that without a Cat.

Dennis



>From: John Goubeaux <john@UCSB.EDU>
>Reply-To: John Goubeaux <john@UCSB.EDU>
>To: vanagon@GERRY.VANAGON.COM
>Subject: SMOG TEST failure
>Date: Fri, 8 Feb 2008 12:07:39 -0800
>
>Thanks to all who provided suggestions on how to pass the "Dreaded
>California Emissions Test"  I was puzzled at how my HC values could be
>so high
>at idle, and pass at 2500 rpm, and that the Cat could still be the problem.
>
>I dredged up my values from 2 yrs ago, when I also failed on the first
>attempt, and passed after putting a new cat on, and I can see that the
>numbers
>reveal that I was basically in the same situation back then, and that
>replacing the cat resolved the problem. At least I have a good idea on
>how to pass this time around now.
>
>I guess one question is: "why did the NEW cat fail after 2 yrs" or did I
>"kill it" with a poorly tuned engine?
>(note i replaced the O2 sensor several months later)
>
>Has anyone else had bad results with the Emico converters?
>
>Does the warranty on these cover failure after 2 yrs? (i guess i should
>read the fine print)
>
>Below are the 3 sets of  emission values.
>
>I hope this info, and discussion, might help other Californians, and
>those from other strict emission states keep their vanagons on the road!
>
>
>Values from 2 yrs ago (first attempt failed)
>********************************************
>
>
>rpm    %CO2    %O2    HC(ppm)    CO %    RESULTS
>____________________________________________
>
>871    8.4    8.5    637    .93    GROSS POLLUTER
>
>2577    13.0    2.3    70    0.76    PASS
>
>
>
>**Replaced Catalytic Converter with EMICO  Model
>
>
>
>Values from 2 yrs ago w/ New CAT (second attempt PASSED)
>****************************************************
>
>rpm    %CO2    %O2    HC(ppm)    CO %    RESULTS
>____________________________________________
>
>861    14.9    .2    63    .01    PASS
>
>2640    14.7    .4    37    .12   PASS
>
>
>
>
>
>Current Values:
>*****************************************************************
>
>rpm    %CO2    %O2    HC(ppm)    CO %    RESULTS
>____________________________________________
>
>915    11.9    3.2    424    0.55   GROSS POLLUTER
>
>2571    13.9   .5    66    0.55    PASS