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Failed Emissions Twice - Colorado

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Faded95

10+ Year Contributor
75
2
Sep 15, 2011
Fort Collins, Colorado
I've read all the emissions threads on here and I'm still stumped:

Last week I failed for high NOx so I did a boost leak test, cleaned out my EGR, cleaned out my throttle body, installed a new BISS o-ring, installed a new ISC o-ring, and fixed a leak in my IC-pipe.

First Test:
HC GPM 0.5796 - limit is 1.2000 - PASS
CO GPM 5.9712 - limit is 15.000 - PASS
NOx GPM 2.8003 - limit is 2.500 - FAIL

Today my NOx was well under the limit but my CO skyrocketed, it's like I went from slightly lean to really rich.

Second Test:

HC GPM 0.7721 - limit is 1.2000 - PASS (but higher than last week)
CO GPM 22.1448 - limit is 15.000 - FAIL
NOx GPM 2.1075 - limit is 2.500 - PASS

What would cause my CO to increase so dramatically? Here are my speculations:

1. I used throttle body cleaner liberally on my throttle body, EGR and EGR ports; could that have caused higher CO readings?

2. I filled up with gas this morning; could a full tank cause higher CO readings?

3. I removed a fitting in the line running from my wastegate to my mbc that had a bleed hole in it; the mbc is a homemade unit by the prev. owner and I'm not sure of the purpose of the bleed hole here. I removed it b/c it was leaking during the boost leak test. Could this cause high CO readings?

4. Could the ECU still be learning the fuel trims? I've only driven 25 miles since all the above mentioned work was done.

5. Longshot here - the ECU that's in the car isn't the same one that was in it last time I passed emissions. I swapped them to try and correct an IAC issue but the ECU wasn't the problem so I still have my old Eprom waiting to be swapped back in.

Any other suggestions? I've read doing an oil change helps but i passed CO last week so it has to be something that changed with the work I did over the weekend.

Info about the car: 95 turbo awd, 3" exhaust w/ flowmaster high flow cat (cat is 3 years old), stock fuel system, 14b turbo, boost set at 15psi, NO wideband, NO engine management system.

Any help would be appreciated - Thanks!
 
They tested my car this morning. All readings were well below limits, but they failed me because they said I didn't have a 3 way CAT on the car. I told them I did, that it was OBDII EPA legal, and that I have the receipt, but they said it didn't matter because they didn't see it when they looked.

W

T

F

:ohdamn:


So I asked them how my emissions would be so low without a CAT, and they said they wouldn't be.

NO SHIT

Now I have to call the state number and get someone to sign off on the CAT. If the state inspector won't, I'll have to change it. Just because the moron looking for it didn't see it.:notgood:

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wow - not surprised though, a friend of mine was failed because they didn't see enough O2 sensors in his GVR4 - he had 3, one more than required...The state inspector will probably pass you when you show him the paperwork.
 
113k on a vehicle built in late 1989 (looking at your VIN number). Some pretty low miles there for the years on the road.

Good sniff numbers as well.

In our state, they lift the hood (I have a catch can which is allowable since I'm reducing hydrocarbon emissions) see if any noticeable mods or vacuum hoses removed, close the hood, do the two sniff tests, pay your ten bucks, you're gone and good for two more years.
 
On my way to the Denver Emissions Technical Center, I called an made an appointment to get a "DR 2365" which is a waiver stating my car isn't polluting or something like that. I'll post again when I'm back.
 
Ok, back from the Denver state inspector dude. He was very cool, apologized for the testing stations incompetence and provided me with a form stating I do have a CAT and it is legal.

However, now I have to go back and get RE-TESTED again. I'll post an update when I do.

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Ok, back from the Denver state inspector dude. He was very cool, apologized for the testing stations incompetence and provided me with a form stating I do have a CAT and it is legal.

However, now I have to go back and get RE-TESTED again. I'll post an update when I do.

At least you don't have to pay for the re-test, glad it worked out for you.
 
I ran back over to the testing center, showed them my new paperwork so I could get tested again...

The guy doing the test this time was on the dyno for over 15 minutes. (It took 3 minutes this morning when I "passed") I watched his screen as he tried to match the speed to the tester thing, and his arrow was hardly ever where it should have been. He was constantly in a higher gear than he should have been (like shifting into 4th at 25mph).

When he was finally done, guess what happened? I failed. And they told me I'd have to pay to test again.

I pulled the manager over to complain, because it was clearly user error that I failed both times. The car was bogging down so bad because the tester didn't know what gear he was supposed to be in.

He apologized and said I could come back for a free test. What a pain in the ass. Now I have to go back in on Monday. What a bunch of #### ups.

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With untrained 'sniff monkeys', is this testing procedure in the State of Colorado actually a fair program to use?

Almost could see lawsuits from vehicle owners going after the emissions program due to their 'sniff monkeys' causing potential damage to the owners vehicles due to them being poorly trained.

I'd be raising hell to the state if some 'sniff monkey' abused my vehicle during a sniff test.

-DSM
 
I'm going back today with my new cat for my fifth test, I expect to pass barring something like your experience Erik. At least the manager is giving you a free test, it'd be nice if they'd compensate you for the time it took to come back again and fuel used in the previous test and travelling to the facility...but it's the state so don't expect much.
 
Damn, I am going to Fort Carson next year.... I know for a fact my car won't pass any type of emissions testing
 
Damn, I am going to Fort Carson next year.... I know for a fact my car won't pass any type of emissions testing

Ft. Carson is in El Paso County and they don't have emissions testing.

Well I passed today finally! The new cat did it's job.

Readings were:

HC - 0.3580 (limit of 1.2000)
CO - 2.6947 (limit of 15.0000)
NOx - 0.8900 (limit of 2.5000)
 
Ft. Carson is in El Paso County and they don't have emissions testing.

Well I passed today finally! The new cat did it's job.

Readings were:

HC - 0.3580 (limit of 1.2000)
CO - 2.6947 (limit of 15.0000)
NOx - 0.8900 (limit of 2.5000)

Nice! Congrats. I'm going in for my free retest tomorrow or Wednesday, I'll be sure to post the results. What CAT did you go with?
 
Erik - I don't recal the brand but it's not a 'high-flow' type. I'll check the paperwork when I get home tonight.

Over my lunch hour I noticed my fuel door was ajar, opened it up and guess what? No gas cap! I called the test facility and aparently this is a common occurence, they told me to come by and fill out a claim for a replacement or possibly get mine back. I ended up getting mine back but not the time to deal with their shortcomings.
 
Went back for the 3rd time this morning, passed. :thumb: (my first 2 "fails" were due to tester incompetence though). At least they recognized that and I only had to pay for the first test.

HC GPM 0.6838 MAX 2.0000
CO GPM 3.4580 MAX 20.0000
NOx GPM 1.8009 MAX 3.5000
 
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