goingboeing737

Car still will not pass emissions. In fact, it's getting worse. I have the dat from last year when it passed(Dec 2002), then where it failed(Dec 2003) and again today(May 2004)

I replaced the injectors, CAT is new from Dec 2002, new plugs, new O2 sensor 2002, new fuel rail, new fuel reg and damper, fresh oil.

The funny thing is, the car runs great.

Where should I look?????

Sorry about the size,,,I have reduced it by 75% and it still shows up HUGE...

83na944

Looks like the engine is running a rich mixture. The HC (hydrocarbons) is high which means that some unbruned gas is getting through. And the CO (carbon monoxide) is also high, which means that the engine is not burning the HC completely (it would become CO2 then).

That's about as far as I can go with the analysis. Maybe worn injectors would cause this. Could a vacuum leak cause it, too?

How certain are you that the catakytic convertor is working? The cat is there to convert HC and CO to CO2, IIRC. Any chance that it has failed already? Also, did you check the fuel pressure at the rail? High pressure would cause more fuel in the cylinders than the DME expects.

goingboeing737

Yea, I can tell it is running rich,,,you can smell it.

Brand new injectors. It is an aftermarket CAT from Midas. I don't know, maybe it could fail after only 1500 miles.

I'm thinking maybe the AFM. Will have to pull it and ohm it out this weekend.

We adjusted the mixture full lean today. (Took out the plug to expose the allen screw) Did not seem to do anything.

Chris Prack

High CO and HC is an indication of a rich mixture. Low CO and high HC indicate a lean mixture.

At 9% CO post-cat your car should have black smoke out the tailpipe and/or the rear of your car around the tailpipe be black also. I am surprised that you say it runs great? I wouldn't expect it to run all that well if those numbers are truly representative of the tailpipe emissions. The plugs should be fouling out at a minimum.

Chris Prack

you posted while I was typing.......which way did you go with the CO adjustment? Screw it in or out?

goingboeing737

No smoke.

Runs like a bat outta hell.

Little soot inside tailpipe. New plugs. Old ones looked real good, they only had 1500 miles on them.

Hard to believe the numbers went worse since Dec?????

Shutemup

weak coil maybe?

same kind of numbers I got when mine was tested while the alternator wasn't charging

Chris Prack

That's a good point. Something is obviously decaying toward failure. Low secondary voltage could produce those kind of numbers.

Chris Prack

I just thought of something. Why did you have the cat replaced by the Midas unit?

goingboeing737

New coil (from previous issues ) Alt is charging good, has updated voltage regulator and new brushes.

goingboeing737

Original muffler had a hole in it and would not pass, replaced it with a used one. Original CAT was bad, could hear it rattle.

Chris Prack

Damn your not making this very easy........ What, other than what you have mentioned, has changed since it last passed?

It makes no sense to me that at 9% it dosen't smoke at all. That is what we call "pig rich", it's VERY fat. If you pull a plug it's not black? Let me think about this for a few minutes..........

83na944

This was a tailpipe test, right? After the cat, not before?

Got a warranty with that cat?

OTOH, there's too much gas going through there. Maybe you're on the right track with the AF. Might check the TPS, too.

goingboeing737

The single biggest change is the new injectors.

They are Bosch, BUT, they have a Chrysler part number. The pittle cap on the end is different that the plastic "hat" that were on the original. These have a concave metal pittle that's crimped on. The company I bought them from "assured" me the are a direct compatable swap.

Only thing I could imagine is they are the wrong pressure/flow rate...??

They were installed AFTER it failed in Dec 2003. Today was the first test with them installed.

Well, my throwout/release bearing is about to go out....not related,,in a normal world!!!!!

I will pull a plug and shoot a pic of it later tonight or tomorrow.

Chris Prack

Is there someone close to you that would be willing to swap injectors and let you retest? What part number is on the injectors? I am willing to bet they are flowing more fuel than the OE units.