[Vwdiesel] 100,000 US Mandated Emissions Warranty?

[Steckly.Gary at ic.gc.ca]

You have my sympathy Nate.  I had a similar problem here in Ontario with a
'91 Berretta that my son bought. It had a 3.1 V-6 and ran like a top
initially, so we figured it couldn't be all that difficult to pass the test.
We were wrong. On the first emissions test, it failed rather miserably on
unburned HC and NOx as I recall.  We changed the O2 sensor, since my
mechanic figured that was a good place to start, and they do age and will
screw up the mixture as their response declines with age. The new sensor
only seemed to make things worse, and the car didn't seem to run as well
either, hesitating and misfiring. Turns out his apprentice damaged the
ignition wire next to the O2 sensor while he was struggling to change it.

So we installed a new set of wires and plugs and again it ran fine, but
still failed the test.  Figured that the unburned fuel from the cylinder
that wasn't firing due to the wire might have toasted the cat, so we changed
that too.  Still no luck... but it ran so well! By this time, the car had a
complete tune up, new filters (oil and fuel and air), ignition wires and
plugs, fresh oil.

So we got a bit more creative.  I had heard stories about hydrogen injection
systems that allegedly enhanced the combustion efficiency when a very small
amount of hydrogen and oxygen (electrolysed directly from a canister of
water), is added to the fuel mixture via the intake manifold.  We built a
small electrolyser from some ABS plumbing parts and stainless steel
electrodes, and tied it directly into the vacuum line. It cleaned things up
dramatically, passed all the NOx tests and HC at cruise, but it was still
failing on unburned HC at idle.  It seemed to be running rich, which was not
entirely unexpected since the extra 02 from the electrolyser can actually
fool the o2 sensor into thinking that the mixture is lean; causing the
computer to call for more fuel.

To counter this, we built a relatively simple circuit that allows you to
offset the signal from the O2 sensor in either direction and essentially
dial in a leaner or richer mixture.

Bottom line... on then final test we received what is referred to as "a fast
pass".  In Ontario, the tests are monitored on line in real time from the
test facility to a central computer somewhere at the Department of
Transport.  If you are close to passing on a test, the central computer will
authorize a "second chance" test and they run you through the test again.
On the other side of the scale, if you are exceptionally clean in the first
few seconds of the test, they give you a "fast pass" and bump you out of the
test even before completing the normal test cycle. After having all those
"second chance" authorizations on the first tests, it felt so good when they
kicked us off the dyno with the "fast-pass" after about 45 seconds or so!

In your state, do they allow you to add your own emissions modifications to
the car? I just called it a "fuel saving device" (which it is) and since I
did it myself, the emissions testing facility said it was OK.  If there are
no prohibitions against adding fuel saving devices to your car in your
state, you may want to consider something like this.  I'm all for clean air
legislation, but sometimes it seems like getting a car to pass the test is
more of a black art than a science.

My son still has the Beretta, but after all that grief, the next car I
bought was a diesel that is old enough to qualify for the exemption from the
emissions test (1981 Mercedes 300SD).  Anything over 20 years gets a
complete exemption in Ontario (they figure that any car that lasts that long
has paid it's "environmental dues" I guess ;-)

It's likely the most efficient, clean burning vehicle I have owned.  40 mpg
(imperial gallons) not a bit of smoke except on cold start-up for a few
seconds, and a range of over 600 miles per tank! My next project is to put
the electrolyser on the Merc and see what happens to the mileage (it is
really supposed to improve the efficiency of diesels - eliminates any
opacity problems and dramatically improves fuel mileage).  After that, maybe
a vegetable oil conversion kit.

Good luck with the Volvo Nate. A '92 Volvo is hardly broken in, in my
opinion, and way to young to retire due to emissions hassles.

Gary
Ottawa, Ontario

-----Original Message-----
From: Nate Wall [mailto:natewall1 at yahoo.com]
Sent: Thursday, July 3, 2003 8:49 AM
To: vwdiesel at vwfans.com
Subject: [Vwdiesel] 100,000 US Mandated Emissions Warranty?


Sorry about the off-topic, but I figured someone here
would know. My GF bought a '92 Volvo 960 from a guy
who lives a couple counties over where emissions
inspections are not required. The car has 90,000 miles
on it. When she had it emissions tested to get her
registration, it failed miserablly. It was about four
times over the limit for HC CO and NOx. New plugs and
an airfilter did not help. Failed the re-test too. A
volvo shop looked at it and said the catalytic
converter and possibly the O2 sensor are bad (Oddly
the car does not have an EGR valve). Estimates are in
the $1,500 range to fix it. The exhaust system is one
complete welded unit!!!! From where it bolts to the
head to the tip of the tail pipe! I thought I read
somewhere that cars sold in the US are required by law
to have a 100,000 miles emissions system warranty from
the manufacturer. Is this true? This is something I've
NEVER had to deal with!!!! Tx,

--Nate