Date: Mon, 1 Dec 2014 17:14:28 -0500
Reply-To: Dennis Haynes <d23haynes57@HOTMAIL.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Dennis Haynes <d23haynes57@HOTMAIL.COM>
Subject: Re: Calif. Smog Fail and Catalytic Converter
In-Reply-To: <201303161625.r2GGP3E54001@sbw.org>
Content-Type: text/plain; charset="us-ascii"
What type cat was first installed? It should not have failed that early
although it could have been fouled. If it was a CARB approved Cat most
likely it should have been covered under a warranty and the failure should
likely need to be documented and submitted to the catalyst manufacture.
Since you have had some experience with knock and ping you are also making
excessive NOx and these conditions can cause catalysts to fail early due to
the excessive heat. As I mentioned in the past there are reasons that VW
used the compression ratios and ignition timing settings along with so many
other choices. Yes the Vanagon engine is de-tuned and NOx control is the
primary reason.
As for someone tuning the engine and setting the mixture the O2 sensor
should have the ultimate control for most cruising situations, even with a
change in displacement. Also, the operation of the O2 sensor is more
detailed than simple mixture control. Check the archives for my past
comments on the o2 sensor and the 3 way catalytic converter.
Dennis
-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
Steve Williams
Sent: Saturday, March 16, 2013 12:24 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Calif. Smog Fail and Catalytic Converter
On 2/16, I wrote about a fuel leak in my '84 Westy that led to replacing the
fuel lines and upgrading the aluminum injector manifolds. Nice to have that
fixed.
The next day, I renewed the registration on-line without even noticing that
it required a smog check. Every two years here in California, I think.
The smog check led to a new catalytic converter, but first some background.
GoWesty installed a 2.3L waterboxer in 2009, four years ago. At that time,
they installed a later-model cooling system and replaced the muffler and
catalytic converter. But they kept the stock air and fuel system and engine
electronics.
Two years later, with 31,500 miles on the new engine, I stopped at GoWesty
on my way from the S.F. Bay Area to L.A., in part to have them set up the
engine to ensure it passed the smog test. At that time, I believed this
installation requires some special knack that GoWesty would provide. (I now
think it's not that hard, as I'll explain.)
They tuned the engine and did some other work, and recommended Smitty's
around the corner, where it passed the smog check just fine.
At the same time, GoWesty found a slight exhaust leak blowing on the water
pump, which was leaking again. But I needed to get to L.A. for the weekend,
and the leaks weren't urgent, so we agreed it'd be OK for me to drive to
L.A. for the weekend and return Monday.
On the way to L.A. and back, I was surprised to see the MPG going down and
down! Arriving back in Los Osos, I filled the tank and calculated 12.9 MPG,
down from an average of around 19.
http://www.fuelly.com/driver/sbw/vanagon/log/1427188
GoWesty found the O2 sensor had failed, apparently just after the smog
check. Seems an unlikely coincidence, but, whatever. The MPG went right
back up to 17.8, and ten days later it turned in 20.5 MPG over a 200-mile
trip. Problem solved.
This month, when I realized a smog test was required, I phoned Peninsula
Automotive in Campbell to ask for a recommendation of a test station. (I
once went to a test station who couldn't figure out how to test a Vanagon,
so I like to go where they see Vanagons all the time.)
http://www.peninsulaautomotive.com/
Peninsula recommended Accurate Smog Check just across the freeway. I drove
down there after work on March 1 for a pre-test. They were very efficient
and friendly. They charged $30 for the pre-test.
http://www.accuratesmogcheck.com/
At this point, I had 43,650 miles on the 2.3L engine. The pre-test failed
due to high NO. This PDF has both the pre-test and the final test last
week:
http://sbw.org/westysmog2013.pdf
Accurate said it looked like the engine tuning was dialed in just right, but
the catalytic converter was shot. I drove over to Peninsula and showed them
the report, and they concurred that a new cat was needed.
I was surprised, because I thought cats lasted longer. Four years and
43,650 miles? I don't actually know. Anyway, they said a failed
O2 sensor can quickly cause early failure of a cat, so maybe that was it.
I was also surprised the other numbers were so good, because of my
impression that the tuning is tricky with the modified engine. But that
doesn't seem to be such a problem. The last tune-up was by Van Cafe in
Santa Cruz last October, after they found the engine was running leaner than
they prefer. I really liked the way it ran after that tune-up: No more
pinging going over the mountain on Highway 17 at full throttle, and the MPG
wasn't affected. And six months later, the other smog numbers were right
where they should be.
Still, I didn't want to have Peninsula install a new cat without a second
(third?) opinion, so I emailed the report to Chris Myers at GoWesty and
asked him whether he agreed a new cat was needed and whether the failed O2
sensor may be responsible.
Chris replied quickly to say yes, he agreed a cat was needed. He didn't
directly answer about the O2 sensor, but he did say, "The new cats sold now
have more platinum and can control NO better." "New"
since mine was installed in 2009, I assume. Chris pointed out their price
for the cat, $260 (plus about $15 shipping) including gaskets and hardware.
Their product page includes some commentary on the quality of cats:
http://www.gowesty.com/ec_view_details.php?id=23533
Peninsula also said cats sold today are better than a few years ago.
Last week, I took the van to Peninsula to install the new cat. They charged
$325 for the cat, gaskets, and hardware. I try not to quibble about price
differences.
Peninsula finished the work quickly, and I drove back over to Accurate to
repeat the test. This time, it passed easily. They charged $65.
(In the two weeks between tests, Accurate had moved one door down Curtner
Avenue to a new, bigger facility. Apparently they've been working on the
move for almost a year!)
Like the work on the fuel leak, I learned a few things from this experience.
It has been a shock to spend all this money on the Westy suddenly, but it
gives me peace of mind to know my escape pod is ready for the next
earthquake or financial disaster, or just a sudden need to chuck it all and
get out of town.
