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Help! failed smog AGAIN

C4C5specialist,
Thanks for getting involved.
I am not sure which brand o2 sensor is currently in there. It's fairly well welded itself in place, so I have to get it on a lift and heat it to remove. Its been there for 10 yrs or more since the stock Y-pipe was removed...
I have a NEW Bosch to be installed, or is the delco a better choice?

Was also going to get the cat tested either by gas and/or temps at ends.

Cannot get printed info yet because nobody so far has the equip to plug in and see what the ECM sees. Around here the shops all moved on and went to later model scanning. I guess classics are'nt that interesting to these techs in this area. One shop tells me that nobody has an OBD1 car anymore....
I guess it is older than some of the techs...wow.

Schrade, I WILL go get a jug of everclear before the weekend. That "store" was closed on sunday so I had to settle for methanol rather than ethanol. I never knew the exact difference between the 2 except that one was for drinkin and the other was for blindness.

Geek,
I wish you guys would'nt worry so much about my reasons for modifying the engine. They were the same as anyone that wants to go faster and have fun with their car. It was torn apart for rebuild and the decision was made to upgrade while apart. NOT to BOLT-ON stuff and hope for the best. The plan was to build and it was very successful.

But, to clarify a couple things,

It WAS NEW, upgrades done on the table, balancing done at the machine shop, and electronic control calculated and set up to match the physical changes. I have only built 2 L-98s but many multi-cyl motorcycle race engines both 2 & 4 stroke for straight line and road course competition. I had to stop short of my goal of all forged parts in the bottom end because of budget limitations.

Notice the little things like the compression ratio...Done intentionally so I would not have to mix gas (av gas +pump gas) or retard the timing or flatten out the advance curve to prevent knocking. It can run 89oct but it has to be retarded a cpl degrees to do that in the summer.

Balanced bottom end, so that upper end RPM could be safely enjoyed when running out 1st, 2nd gear and drop it into the middle of the powerband shifting into 3rd for stop-lite steeple-chase.
Another goal was to keep the stock engine equipment (for smog and resale) but get a REAL gain in HP and not just take some from the other end of the power band, (like renegade owners will likely suffer).
This engine with the big exhaust and 4 corsa exit pipes would rev from idle to 6000 instantly, and almost do it as fast when it was in gear. It's been a VERY good build. The exhaust was later replaced with a muffled system so I could hear the phone or talk to someone in the car.
I've detuned (mufflers, main-cat, intake filter, etc) to make it more civil and quieter, and focused lately on restoration of the appearence and the interior finish. I am trying to get it back to "new condition". But I do not have a garage to work in, or a scanner that reads and prints out a report, I can only go as far as what a digital multi meter and whatever lites, buzzers and personal experience will tell me. I am here asking the professionals for their opinion becasue my C-4 experience is limited to 5 cars,. only 2 of which I built, and I see people in here that lay hands on them everyday and have done so for many years. A fresh pair of eyes is always helpful.

Moving forward,
It does not have oil passing the rings on #7, with compression test as proof.:thumb If rings were an issue, 7 would have been low. That was the point of the compression testing. This was to rule out physical damage and oil as the reason for the dirty plug. Had the comp been low in #7 and I was able to get it up temporarily by squirting oil into the cyl, thats a sure bet that there is ring damage or wear. But, thats not the case here. The cyl is tight.

I greatly appreciate your help, as I am aware that there are many people here that are smarter than I ever will be.I need your expert advise in order to learn,and that is really the goal. By presenting all the available info for you guys to digest and consider, I can make decisions on what & how to approach the problem tomorrow. Anybody can throw the problem in the lap of some shop and say "fix it". I would rather understand what was wrong, how and why it is like that. That comes from careful study of the condition and learning from those that have a better education and seen things that I have not.

I'll work today to get a printed report and post it here. I have no idea where I'll get it, but someone HAS to have the scanner to do more than read DTCs and actually interface with the ECM thru the ALCL. I cannot believe a city this big and they all abandoned OBD1 diagnostic equip.

Current facts include:
no oil burning.
no oil/exhaust blow-by thru pcv.
engine tuned to factory spec with factory ecm & prom.
inj solenoids all test ok, fuel press leakdown was good.
operating temps are currently factory spec.
One spark plug thats dark brown. & others that are white. All are new.

Questions at this point:
is A.I.R. system operating correctly? needs to be tested.
is #7 injector shooting excessive fuel when its pulsed?
Is the cat dead?
is the o2 sensor partially to blame?


Because of discussion I now have eliminated many possible issues and repaired several things that were unknown until digging into the emissions system. Anyone of these things could have been more trouble somewhere down the road, but thats been prevented with the help of this group.
I'll continue to attack the issues with the advise of the group, as I feel that its been sound, rational advise and not BS which only serves to distract.

It's time to make some calls and find a real diagnostic scanner in this hillbilly town.
Again,
Thanks guys.
 
boomdriver ...... are there any corvette clubs in the area that you might be able to ask about the OBD1 scanning issue? Maybe some of the guys that have cars around the same age as yours would know of a place to go for that. Maybe even an F-body club.......
Just thinking out loud here......
Andy
 
HI there,

Bosch o2 sensor is just fine.

Remember, the ECM sends 450 millivolts TO the sensor.

Your sensor reacts to the oxygen content when its HOT!

If its getting correct source voltage, and the signal fluctuates between 100 millivolts and 900 millivolts, you know that the PCM is constantly adjusting and that shows you that your AFR is normal.

So, that being said, I would start by using a QUALITY digital multimeter and monitor your o2 sensor voltage when its hot at about 2000 rpm to determine if its working and the PCM is compensating.

If your voltage when running is FIXED, either high/low or static at 450, then you KNOW you have a problem with AFR and will have to address it.

I truthfully believe that you need to ignore the rest and start here.

If your o2 sensor and PCM are working correctly, and you would know by this test, the ONLY other issue would be your converter.

AIR INJECTION will be AFTER the converter and would lower your HC reading, so you know thats not part of the problem.

Allthebest, c4c5
 
Thanks for the detailed info, its appreciated.
My meter is starting to act up, so it need to be replaced. This is good reason (justification) to buy a new one...lol

Also believe the problems have come down to the o2 sensor OR the converter.

What are your thoughts on the #7 plug being so much darker than the rest? I should have taken pics and posted while it was out yesterday...still might do that. If that IS rich than its just inches above the o2 sensor. O2 is just under the collector, driver side.

and the converter is about 2 yrs old but it was a generic cheapie. This one does have air injected upstream at the inlet. The tube was broken under the check valve, but thats been repaired. I can feel exhaust coming up thru that tube when its opened.
The new air pump is making noise, and has a rough spot in the rotation so thats getting replaced warranty. dont know if that makes a difference or not...
 
Andy, Great thought !
I was going to go drive over to a commerce park where I was told of a C-3-4 shop. I know of one club close by but its mostly c-6. I'm going to quiz my parts guy also. need to see if my ABS sensor arrived yet...
 
HI there,

#7 could be an atomization problem with the injectors. Although I have seen this before, its rare.

I would run a bottle of Techron or 44K through just to make sure there isnt an injector flow issue.

Otherwise, test your o2 sensor FIRST to make sure your getting compensation and changes in voltages. This will eliminate the need for data from the ECM.

#7 is only 1 of 4 exhaust streams so even if that one was an issue, you would get the other 3 to balance out.

Allthebest, c4c5
 
boom, believe me, Bill (geek) isn't bad mouthing you for modding your car, his 84 is FAR from stock. It just makes a difference in his trying to help you trouble shoot. :D :thumb
 
Geek,
I wish you guys would'nt worry so much about my reasons for modifying the engine. They were the same as anyone that wants to go faster and have fun with their car. It was torn apart for rebuild and the decision was made to upgrade while apart. NOT to BOLT-ON stuff and hope for the best. The plan was to build and it was very successful.


What Tom said...

I have NOTHING against modifications! (crikey you should see some of mine :chuckle) I just didn't realize yours was modified...and that makes a big difference vs. stock when it comes to this kind of troubleshooting! Just spoke too soon, that's all.
 
No worries Geek,
I DO get some attitude from some folks that assume that all I did was slap some bolt on junk in place and claim to have HP...just like the advertisements said...lol.
No, this motor was built with intent. The goal was to utililize the GM engineering to keep its solid reliable nature, while enhancing the design to maximize HP & Torque and keep the wide power band but allow it to have less dramatic fall at top end. Heck, the old stock motor practically shut off at 5500. This one still pulls at that speed. With the big exhaust, it was scarey how fast it revved. But, the sound was TOO much when just cruising. Could'nt even talk to a passenger when on the freeway and I got tired of scaring children (men, women, dogs, truck drivers, everyone pretty much) in other cars...So I went back to a muffled exhaust system.
In building this one I removed the evidence of production or assembly line and made things fit together better, matched passages, found balance in exhaust back pressure and intake restriction. There was LOTS to be had by re-assembling as if it were a hand built, one of a kind motor. I really wanted to go with a forged rotating assembly but I was blowing thru the budget so fast on the top end that I settled for balancing the stock crank/rods/pistons. Machine work was the majority of the expense and I did the polishing inside the TB and matched that to the plenum myself.
Did'nt really save a dime because I burned thru 3 dremmel tools just on the TB. Home Depot got suspecious after I returned the 2nd and said "i don;t know what happened to it, the thing just quit"...uh huh. One actually caught on fire.

The bore was not by choice...That was disaster clean-up or resleeve. I decided to just go for the added mass and make the required adjustments in fuel/air for the larger displacement.
The compression was more a by-product of the bore and what pistons were available. I was open to more machine work if the calculated compression started to approach 11. That was unacceptable in my opinion for a street driver. I did not want to go to the airport to fuel up each week....So, its kind of stock, in design at least, with some other parts installed. Even with the current smog issues I'm looking for some new valve springs and roller rockers.:eyerole
I just can't leave well enough alone...

Now, test results...

C4C5specialist...
I checked the o2 sensor using your method and found it to be fully functioning. The Voltage output is fairly stable with fixed rpm, but moves instantly with throttle up and down. It generates zero until hot. As old as this o2 sensor is I expected it to be an issue.
I ran some Lucas injector cleaner thru it last month, but I have been concerned that there was a flow issue with one of them. Sometimes, not always, the engine feels like it has a mis or an odd sound. I was worried that some trash may have been in the rails when we had the heads off last summer. I might be buying a set of FIC injectors soon anyway....

I AM replacing the AIR pump because it is making noise and It has a rough spot.; The output is also poor. That MAY contribute to a weak reaction in the exhaust stream. One thing, I was unable to confirm operation of the diverter valve,. electrically the plug has v on both sides and a ecm ground closes to operate like the a/c clutch. With the poor air pump performance I was not able to feel any flow but the silencer seems to be loud.
 
The Voltage output is fairly stable with fixed rpm, but moves instantly with throttle up and down. It generates zero until hot.

Been a while since I looked at narrowband O2 sensor output...but that doesn't seem right. As I recall once the ECM goes into closed loop and at a constant RPM you should see the voltage swinging between 0.1-0.2V and 0.8-0.9V (do this at 2000RPM or so as Paul suggested to really see the effect). At no time should the O2 sensor read zero volts, even when cold...at that point it should be reading close to the mid point of 0.5V.

Paul can elaborate more...or correct me if my O2 sensor memory is rusty (or maybe carbon fouled :L ).
 
lol..
I'm not the one to be correcting anyone around here!
I am going to go back and look at it again because I've already forgotten where it was, at what rpm and so forth but it seems like cold it was something of a solid output once I got the connection good with aligator clips. Kept burning fingers trying to reach down there with the meter probes....
Anyway, I ran it up and observed that at about 2000 that it varied slightly but was more or less stable, but it would respond instantly to throttle changes,. I'll make notes next time. I'll do that after I change the air pump tomorrow.

I am starting to think that all is well in the eng management dept. Today I cleared a series of DTCs that were all anticipated and were exactly what should have been there after cranking with the dist HEI wire off, and running with the o2 sensor d/c.
 
Yeah record that stuff...voltage swing/frequency vs. RPM (it should "swing" much slower at idle than at 2K).

Keep trying to find someone that is able to scan what's going on with it...the BLM numbers that Paul mentioned (among other info) would be oh so very useful.
 
I will find a real scan somewhere and I will document the o2 output just to verify that its sending the required data.
I need to find out why #7 is burning dark brown when all the others are white to off-white. Its a dramatic difference and I really think that there was trash in the rail when it was apart a few months back. Since compression is exactly what it should be, it has to be fuel related.I'll pull the valve cover this weekend and look at the valve seals to see if that one got up and left.
Sometimes the outside cyl will run colder than the others but thats not very common. besides, #1,2, and 8 are burning white and even after several years I still cringe at the thought of something not being "right" with the investment in this engine...

I will post the o2 outputs tomorrow afternoon.
Thanks again.
 
It doesn't necessarily "have" to be fuel...it can be oil. You might also compare the temperature of the header out of that cylinder vs. the others.
 
HI there,

Bosch o2 sensor is just fine.

Remember, the ECM sends 450 millivolts TO the sensor.


Allthebest, c4c5

c4c5,

is that source voltage for the single wire o2 sensor? Does this 1 wire act as a 2-way path somehow? or is this sensor totally responsible for the signal?
I just want to make sure that the single wire o2 sensor has the value range that you describe.
Thanks!
 
HI there,

That sensor is bad, change it.

You have 450 millivolts on that one wire TO THE SENSOR.

Now, remember, that once the sensor warms it toggles that signal high to low between 100-900 millivolts.

When you have the sensor up to 2000 rpm, that sensor should be kicking voltage up and down VERY VERY QUICKLY.
Almost so quickly you cannot determine your actual reading because its always changing.

Replace the sensor, test for 450 mv on that wire BEFORE you connect it.

As long as you have done this, I will guarantee that you things will get better and you will NOTICE a change in how it runs.

Allthebest, c4c5
 
It doesn't necessarily "have" to be fuel...it can be oil. You might also compare the temperature of the header out of that cylinder vs. the others.

true, I'm just runnin out of places where oil could be coming from....
a valve seal is about all thats left. I wonder what the temps would be at the header tube flanges?

If it were related to rings, I should have seen low compression by at least 10% or more. This compression was so even and consistant that I thought the gauge was bad until I finally got to a cyl that was about 2 or 3 lbs low. I ran that bank 3 times to be sure.

I'm gonna TRY not to become obsessed with #7....it just bugs me!
 
HI there,



When you have the sensor up to 2000 rpm, that sensor should be kicking voltage up and down VERY VERY QUICKLY.
Almost so quickly you cannot determine your actual reading because its always changing.

Replace the sensor, test for 450 mv on that wire BEFORE you connect it.



Allthebest, c4c5

Well, that is exactly what it was doing and why I cannot tell you exactly what the readings were. it was moving constantly but more radically as throttle was moved. I was unaware that there was a signal from the ECM....I will test again tomorrow but plan on changing it anyway.
Thanks !
 
HI there,

When you have the sensor up to 2000 rpm, that sensor should be kicking voltage up and down VERY VERY QUICKLY.
Almost so quickly you cannot determine your actual reading because its always changing.

That's an excellent point...the meter may or may not be able to respond to the rapid swing quickly enough...most for sure won't be able to. However it still should not just sit at "some" voltage...he might just see it jump from say 100 to 900 without seeing what happens in between. And of course zero volts should never happen!

Either way I didn't think what he was measuring sounded right!

Boom...think of the voltage from the ECM as a "reference" point...in other words it has to know where to start (so to speak). It does this with stuff like TPS and MAP (or MAF) sensors as well...albeit in a different fashion but still provides some "reference" voltage. With the O2 sensor the reference point is in the center of its range (450mV), and the sensor varies this voltage above and below the reference point based on the oxygen content present in the exhaust gas. The reason it is only a single wire is because the current return path (or "ground") is provided through the mechanical connection to the exhaust pipe. (some later heated sensors provide a dedicated ground connection).

I'm gonna TRY not to become obsessed with #7....it just bugs me!

:L I can so relate..it'd drive me batty too! As for rings...remember you have compression rings and oil rings...not impossible to make good compression and still have oil getting by.
 
I used a digital meter and that thing was scrolling numbers so fast that I could'nt find the decimal point or the 2nd number by the time I saw the first ! It was changing its data stream at blinding speed.
I'll get SOME numbers off it tomorrow...
 

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