Failed smog

Yeahbro

NAXJA Forum User
Location
Longbeach, ca
Hey guys I just had my YJ smogged and it failed:banghead: It's a 1995 2.5L manual SE model. I know you guys are pretty good with diagnosing this stuff so I was hoping to get some suggestions on what to fix/replace to get it to pass. Here is pic of the exact numbers. Any help would be greatly appreciated.

 
I believe with your clean HC/CO numbers the High NO numbers indicate a poorly(non) functioning catalytic convertor.

Could be other causes though, so wait to hear what the experts add to the mix.
 
Looks like your running lean.
CO readings are low.
O2 readings are higher than normal.
Lean condition will raise NOX

Look for vacuum leaks
Check fuel pressure
Possible that converter might not be working properly, but check vacuum leaks first
 
Grossly elevated combustion temperatures, failed EGR, lean AFR, or failed/failing catalytic converter can all cause high NOx.

Elevated combustion chamber temperatures may be caused by lean burning (which pushes flash temperatures up,) deposits in the cooling system (which inhibit heat transfer,) or deposits in the combustion chamber (which can not only inhibit heat transfer, but retain heat in their own right!)

A lean AFR will also result in zero measurable HC and CO - since you're not getting enough fuel to combine with all the air, the oxygen will be aggressive. Since you still have measurable HC and CO, we can probably rule out lean burning (another Sx of lean burn will be elevated operating temperatures.)

I don't know if your engine/year will have an EGR valve - if it does, a simple test is to open the valve manually at idle - the engine should stall out. If it doesn't, replace the valve or clean the passages.

The catalytic converter is a two-stage (three-way) device - one stage finishes the combustion of HC and CO, the other reduces the NOx to N2 and O2. One stage may fail with the other continuing to work (I believe the NOx reduction stage is first, this provides free oxygen to finish combustion.)

I'd probably consider a replacement of the cat (probably lost the reduction stage,) and clean out the combustion chambers - I've detailed how to do that with just a spray bottle of water/alcohol mix, you should be able to find it with a brief search & some creativity.
 
I agree with the previous posts and add the following:
Check the O2 sensor(s), specifically the voltage to the 02 heater. Check also for any exhaust leaks upstream of the 02 sensors. There are many posts about low voltage to the 02 sensor heaters causing a lean burn.
I just got my XJ to pass, barely, by repairing my exhaust manifold leak and running cooler heat range spark plugs, but my NOX numbers were much lower to start.
 
So far today I did a full tune up and oil change. Did plugs wires cap rotor fuel filter and oil. I was thinking of throwing am O2 sensor in and seeing if it will pass tomorrow. The cat has been replaced at some point (it's obviously aftermarket) but I have no idea just how old it is. I do not have an egr so that's ruled out. I have also checked everywhere for vacuum leaks and it appears I'm good on that one. Plugs didn't look bad either so I don't think it's a lean condition. Can any here tell me the proper way to check voltage to the O2? I would like to rule that out and then maybe try a new cat.
 
So fail number 2
So far I have done
Full tune up
Fuel filter
SeaFoam in intake and fuel
Oil change
O2 sensor
Found a cracked vacuum plug and replaced
Checked for exhaust leaks
Number came out pretty much the same. Suggestions?
 
Well after searching high and low it looks like I have about a 6 inch crack in my exhaust manifold. Odly enough it doesn't sound like I have an exhaust leak at all. I guess that might explain why the No is so much higher at lower speeds.
 
I bought a new manifold and started installing it. The flanges that the mounting washer sits on are a lot thicker on the new manifold. Is this going to cause sealing problems from unequal torque distribution? I guess I can just use a grinder to make the flanges on the exhaust match the intake.
 
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