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240 emissions problem 200 1984

Fellow Bricksters,
I have been watching this board for awhile and I've learned a great deal from it. What a great resource! I'm the proud owner of a 1984 240 GL with 188k miles. The car looks nearly new and runs great. Except according to the state of Maryland. They seem to think that it emits too much NOX. The readings for HC and CO were excellent. It seems to me that the car must be running too lean. I've found a few leaking vacuum lines, and gave Sponge Bob (square car) a shot of BG 44k cleaner. After an Italian tune up on the highway, the previous hesitation was gone and power was up. Yesterday my wife took him in for another emissions check and he failed NOX miserably. I should mention that we have to run 91 octane or we get knocking. I was going to remove and check the knock sesnsor, but holy cats, it's buried!

A good friend who is a Mercedes mechanic (OK I admit to having a Mercedes 240d also) and has owned Volvos suggested a number of things. I have checked the O2 sensor, but my meter isn't fast enough, though I did get movement. One thing he wan't sure of was whether the 1984 240 had a 2-way catalyst (non-NOX) or a three way. Maybe it's just a bad cat? Recently, I've noticed a rattle in the exhaust that I can't find - broken cat? That would be easiest I think. Is it possible to bolt on a new cat without much cursing a bleeding? If the 84 has a 2 way cat, can a 3 way cat be installed to clean up NOX?

I can't put alot more money into Sponge Bob. Any suggestions? I'm thinking O2 sensor and cat. Maybe a timing change could get me to pass? Any help appreciated!

Current readings:

HC= .7968 Standard is 1.8 GPM
CO= .7212 Standard is 30 GPM
NOX= 4.4220 Standard is 2.8
CO2 =342.7 GPM. No standard








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    1) Yes, your cat is a 3-way.

    2) Plug your ignition control module vacuum input for the test. You should find a vacuum line running from the TB over to the ignition control module on the passenger fender behind the headlights (black box with a vacuum transducer at the bottom.) This is a Chrysler ignition computer, and it is of the 'lean-burn' philosophy. It will try to advance the timing up to 52* as soon as you crack the throttle open, and it will hold it as high as it can w/out detecting knock. This makes for excellent mileage and power, but NOx suffers. Volvo issued a recall on this, and fitted some vacuum delay valves to try and correct for it (you may have these installed in the vacuum line, a green/black valve, maybe a black/white one as well.) These really only served to cause a lot of knocking and other unpleasantries. I run my '83 w/out delay valves, as originally intended. But with that background info out of the way, here is what you really need to know - if you plug the vacuum line at both ends, the ignition unit defaults to a very mild, conventional spark advance curve. You'll be down slightly on power, buth the engine will likely sound smoother & quieter, and best of all, your NOx will definitely be reduced! There's no telling if it will be enough by itself, but it's probably worth trying before you do another step.

    3) If #2 does not do enough, you can test your O2 sensor to see if it is working properly. If not, get a new O2 sensor.

    4) If #3 is not enough, a new cat may be required. That's about all that could be involved.
    --
    Speed Racer, '83 240 R, '74 164 E, '93 940 OL1 (Manchester, CT)



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      Thanks for the advice. GT6 - I was under the impression that the Chrylser system used a distributor with a white cap - mine is blue. Maybe the change was mid-year? I'll see if there is a vac line to the ICM.

      If this isn't a Chrysler unit, is there something else I should look for?

      Maryland is going to charge me for each emissions test now, so I'm going to try everything I can. For about $100 I can get a cat and O2 sensor. Anything I'm missing?

      Thanks for everyone's help so far. This board makes owning a Volvo that much better.



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        '83 and '84 B23F's got Chrysler ignition. Most '84s got a Bosch distributor, but it's still a Chrysler control unit.
        --
        Speed Racer, '83 240 R, '74 164 E, '93 940 OL1 (Manchester, CT)



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    You mentioned that you use 91 octane to avoid knocking. Maybe your timing is too far advanced. I think retarding the timimg a bit will lower NOx. I think AyeRoll has posted about this before.
    --
    '80..245..M46...b21a..SU carb..



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    My story was comparable to yours (1984 DL, failed New Jersey dyno emissions for excessive NOx). I brought it to my favorite indy shop and they figured a new cat was needed. Put one on, and the car, retested, passed gloriously.



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      So it sounds as though the cat is a three way on the 1984. Can anyone confirm that?



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    i would suspect your cat too. do they drive them on a dyno at 15 and 25 mph when they test them? here in california they drive them and if your cat is bad youll fail on nox for sure. it is a 3 way cat but infortunately you dont have egr which helps on nox a lot.here in california the standards are constantly changing to keep a fail rate of 10% of all cars tested. seems kinda bogus, if your running really lean even with a new cat you still might fail so check your air mass meter it should be running with the o2 sensor disconnected about .6 or .8% co.



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