85 22RE bought in SF, passed smog because of PO's bro deal. I brought it in for the biannual dice roll. It passed the test, but I didn't have a CARB sticker for the rusty mess of a header. Tech says, "Bring in a sticker, and we'll pass it." Cool, except I don't have a sticker. I can't even tell what brand of header it was in order to try and obtain a sticker. No worries, I'll just buy a header and bring the sticker in and then return the whole deal. Cool, except I went and bought an LCE header, which has the CARB EO # engraved on the flange. Crap. OK, install the new header, that'll fix the problem permanently, it's just money, right? Cool, except the LCE header is longer and has a flange where the PO setup is booger welded front to back. Crap. Sawzall everything apart, install LCE, buy new tubing to put cat and muffler in right spots, extend O2 wire since it's further back now. Return to SmognGo, point to flange "See there's the EO#!" Nope, gotta run the full test again. OK, it passed before, no sweat, right? Crap. It fails. First test looked like this: | %CO2 | %O2 | HC (PPM) | CO (%) |NO (PPM)Test | RPM | MEAS | MEAS | MAX | AVE | MEAS | MAX | AVE | MEAS | MAX | AVE | MEAS |15mph | 1548 | 16.2 |0.0 |146 | 57 | 72 | 1.04 | 0.21 | 0.03 | 795 | 363 | 509 | Pass25mph | 2547 | 15.4 |0.0 |118 | 43 | 29 | 1.32 | 0.23 | 0.01 | 855 | 370 | 583 | Pass After new header install, exhaust rework, O2 wire lengthening, the test results were: | %CO2 | %O2 | HC (PPM) | CO (%) | NO (PPM)Test | RPM | MEAS | MEAS | MAX | GP | MEAS | MAX | GP | MEAS | MAX | AVE | GP15mph | 1623 | 10.8 | 0.7 | 146 | 335 | 326 | 1.04 | 2.34 | 5.40 | 795 | 2123 |21 |GROSS POLLUTER25mph | 2654 | 11.3 | 0.1 | 118 | 285 | 280 | 1.32 | 2.62 | 5.41 | 855 | 2245 |463 |GROSS POLLUTER WTH? It looks like the smog monkeys messed up the NO entry because that's exactly how it appears on my printout. But that doesn't eliminate the fact that I went from passing quite nicely to becoming a gross polluter. It would seem my header install experienced a few problems. The maxim says that whatever you last effed with is most likely the source of your current troubles. So, going back over the fiasco that was the total exhaust rework, I verified that the header was on tight and not experiencing any leaks. Check. The o2 sensor may be original, it's at least suspect now since I touched it, so time for a new one. The cat was a bit rough and got knocked around during the rework, so maybe the guts got scrambled, so, a new one of those, too. Of course, it wasn't a simple R&R, because the new cat's inlet and outlet dimensions weren't measured the same as the old one (2 1/4" ID vs. OD), so more pipe work needed. The final product is the LCE header terminated in a flange, connecting to a flanged slip fit stubby. The slip fit pipe contains the O2 sensor. It uses a u-bolt clamp for sealing (with hi-temp sensor safe RTV for insurance). The O2 sensor pipe connects to the cat with a 2 1/4" OD to 2 1/4" ID adapter. Another adapter connects the cat to the rest of the exhaust which is fully welded together. Whee, time to go back to Smogngo! |%CO2 | %O2 | HC (PPM) | CO (%) |NO (PPM) |Test | RPM |MEAS | MEAS | MAX | GP | MEAS | MAX | GP | MEAS | MAX | AVE | GP |15mph | 1657 | 14.0 | 1.7 | 146 | 335 | 35 | 1.04 | 2.34 | 0.00 | 795 | 2123 | 2383 | GROSS POLLUTER25mph | 2609 | 15.2 |0.3 | 118 | 285 | 14 | 1.32 | 2.62 | 0.00 | 855 | 2245 | 959 |GROSS POLLUTER Arrrgh! Really?! Tech says I should look at my EGR. OK. Remove EGR. Not plugged, kinda dirty. Clean it out with Carb cleaner at both ends. Test pintle actuation with calibrated mouth vacuum. Visually verified of proper operation. Reinstall with new gaskets (had to order the paper one at the head online, no parts store could even get it!?). Pain in the butt. Checked EGR vacuum modulator filter. When EGR activated while idling, it dies. EGR operation check. I'm really kind of puzzled now. Why would it pass so nicely the first time and fail because of high NOx the last time with all new components and nothing else changed? Time for a second opinion. I look for a Sacramento area shop that I think might be able to figure this out, but the best I can do is a well-yelp-rated smog test and repair place. So I take it there and give the guy the three smog test results and go over what I've detailed here. He starts the truck up and runs a stethoscope over the header looking for a leak. He doesn't say he hears one but posits that it may be leaking before the O2 sensor. The next day, he says the O2 sensor is stuck lean because he performed a propane enrichment and the sensor output did not go full rich. He states there is a lot of exhaust leakage before the sensor and cat and that if I have everything fully welded and replace the O2 sensor (with a Denso unit, not the Bosch that I used) he'll continue the troubleshooting process. So now we get down to the brass tacks of my situation. As far as I can tell, high NOx emissions are caused by a lean-burn state. That can be caused by timing, O2 sensor reading richer than it is, or EGR failure. There has been no alteration of the timing from the beginning. The O2 sensor is a brand new Bosch replacement unit. I don't see that brand should matter. I am looking into the FSM to actually run a test on it to see if it is, indeed a failed brand new part, in which case I will replace it with a Denso to hedge my bets. In any case, if it was stuck lean, wouldn't that result in a rich fuel mixture which would cool the combustion chamber temps and reduce NOx at the cost of higher HC? I have verified that the EGR valve is not clogged and does operate as it should. I've inspected the exhaust junctions and do not see any evidence of leakage before the O2 sensor ( which should still result in a richer mixture, right?). What I'm hoping for is that one of you has some insight into the smog results I've experienced and can point me in the right direction for resolution At the very least, maybe someone can recommend a shop that knows the 22RE well enough to diagnose my issues. I've seen Yodaman in Santa Rosa get shout outs, but he's almost two hours away. If he's better than anyone else closer to me, then, by all means, I'll travel the distance to get this done. This truck has sat for quite a while waiting for me to finish up my Jeep (which is now broken FML) and I am really looking forward to having this as my DD. So, by all means, if you have a suggestion, please let me know. TL;DR 85 22RE failed smog, need a good shop in Elk Grove/Sacramento area or beyond, want to drive.

 

Apologies for the mess. I don't know what I've done, and am requesting assistance to unravel this monster.

 

Check your private messages.

 

OK! After a discussion with dark fairytales, I now know more than I did before. It boggles my mind that the brand of O2 sensor would make a difference. So, NGK or Denso it will be. I'll also check the plugs for compatability and give the TB a cleaning. I feel better that at least I have a plan to move forward. I'm really looking forward to making this my DD. Thanks dark fairytales!

 

Victory is mine! At least for another two years... I passed smog this morning, so I can finally make this sucker my DD. Man, what an ordeal. I would not wish CA smog rules on anyone. On the plus side, I am running cleaner than ever. Thanks dark_fairytales for the help.

 

Is all of California this awful? I mean it's a 35 year old vehicle... Good grief

 

Second the thanks to Dark_fairytales.
So the O2 sensor fixed it? Which one did you buy? Part Numbers pls?

Yep. Unfortunately only the 1975's and earlier are smog-exempt

 

I am happily driving my Yota now that she passed smog, it only took a new catalytic converter, 8 new valve guide seals and an EGR valve.
The head rebuild took care of the oil burning but, that oil messed up the cat that was only two years old so I had to buy another one. PITA

 

Well, I can only speak for Sacramento County, as it's the only place I've lived (in Cali) for the past 29 years, but, yes, it's awful for anything other than a stock, newer vehicle. If you buy brand-new, you don't have to smog for six years, otherwise, it's every two. Pre-1975 are the only years that don't have to smog, and other exemptions like kit-cars, and things of that nature. It would be nice if the 25 year old rule was still in effect, but I think we all know what that would do to new car sales here.

If you go so far as to modify your vehicle, that can add to the headaches. I added a Mopar MPFI kit to my 86 CJ7 with a CARB exemption number, and I still had to go to the Bureau of Automotive Repair to get a special sticker because the local smog shops kept failing it for reasons that were covered under the E.O. #. One guy gave me grief because I ran the air filter to the cooler side of the engine bay instead of right next to the power steering pump and close to the exhaust manifold. That same guy gave me a fail because I had an elbow in the PCV hose running to the air cleaner. In their defense, I don't know if I could keep all the iterations of the rules straight, either. I imagine it must be like the tax code, with $10k fines if you get it wrong.

My Toy issues started with a lack of a CARB EO sticker for the header that was there from the PO (who got it to pass smog without it). Even though the tailpipe emissions all fell below average numbers, they wouldn't give me a pass because they had no proof that some manufacturer had paid the state many $K's to ensure it wouldn't impact emissions. So for anyone thinking that the smog program is there to ensure clean air, think again. If that were truly the case, why wouldn't there be just a sniffer test? If the emissions are acceptable for the year, make and model, why should anyone care what's under the hood?

 

I bought the Denso 234-4050 from Autozone. I will install a four-wire Denso soon, but it's not smog legal, so I had to replace the Bosch single-wire unit that I had previously installed because the Japanese truck didn't like the German sensor. I just have to find a switched hot wire under the hood to connect the relay to for the heater.

 

Right? Even Massachusetts got smart and enacted emissions requirements only if the vehicle is newer than 15 years old...their other vehicle regulations are part of the reason I moved recently!

 

You are very welcome ducdug, i know the relief you are feeling after passing.