I've watched this forum off and on for some time, knowing someday I would need help. It's someday. Just had my 85 240 turbo wagon B21F emissioned and it failed the idle speed portion miserably. The standard for CO in Utah is 1.20, my car tested at 11.29!
The stndard for HC is 220, and mine tested at 619!
The high speed (2500 rpm) passed both, barely.
There is no test for NOX here.
Also, I've noticed a lack of boost from the recently replaced (2000 miles ago) turbo. The boost guage barely gets into the yellow and the car is a slug.
Any ideas? I've searched the forums and am thinking plugged catalytic converter? The converter is welded, not bolted, into the down pipe, so not so easy to remove. Any other way to test it?
Other info: new oil, filter, plugs, wires. Last time it was tested, more than a year ago, the shop "adjusted it" to pass, so I am wondering how to arrive at a baseline for mixture etc. It ran terrible after their adjustments, and I would rather do it properly this time.
Thanks, Greg

Greg, I would check all the vacuum lines first,then the turbo hoses.If you have intercooled check the hoses to it and the one to the intake.Any of these can cause low boost if there is a leak.Have you checked the fuel air mixture,that could also be out of adjustment.To check if the cat is clogged there is a bolt in the exhaust pipe just after the cat.remove the bolt and take it for a ride,if the boost gets better then the cat is clogged.I hope this helps,Charlie

Thanks Charlie, I've checked all the vacuum hoses and the turbo hoses, and found none to be suspect, or even brittle at the ends. Several were replaced last emissions attempt about a year ago by the shop that did the "adjusting", so I think I'm good there. There was an exhaust leak at the exhaust manifold gasket then, that somehow sneaked by the test last year.
I've just replaced the manifold gasket(s) and buttoned up a suspect joint in the exhaust further downline between the two mufflers.
I'm wondering if the previous adjustments, done with the manifold leak, are now throwing the system into disarray as far as fuel/air mixture. And I still suspect the clogged cat issue, but I don't see a bolt in the pipe near the cat before or after. Any further hints? Thanks so much for your time. Greg

Greg,Yes the manifold leak was a problem,now that you changed the gasket you need to adjust the air/fuel mixture.Your cat must have been changed at one point with a aftermarket one thats why there isn't a plug.The plug was a test point for emissions.The other thing I thought about that also could cause low boost is the waste gate could be stuck.It's under the turbo and connected to the wastegate actuator or the actuator could be bad.Sometimes the rod will fall off but you wouldn't get any boost. You said you fixed a exhaust leak between the 2 mufflers??? A turbo should only have 1 which is at the the back behind the gas tank.Unless you mean between the cat and the muffler. Let me know if this helps.Charlie

Hi Charlie, thanks for the info. I'm twisting in the wind now for sure. I have a cat, a mid muffler and a rear muffler. As far as I know, it's been like that for at least a couple years. Another family member used the car for about a year, and had the exhaust repaired/replaced during that time. So it's possible the mid muffler was addedd by mistake then...could this be the root of my problems?
I also have a hunch that my mixture is way off, not because the car runs poorly; it starts, idels and revs smoothly, just low boost/power, but if it was adjusted to pass with a manifold leak, then I'm sure the mixture is off now that the leak is gone.
Is there a hint or trick to finding a baseline for mixture adjustment, or a "zero" point of sorts that I can shoot for? ie. leaning until rough idle back up a bit, or enriching until loading, then back a bit? I know I'm shooting in the dark, but any advice is like mann at this point.
Thanks for your help. Greg

Hi Greg, One thing you need is a Bentley Manual or Chilton if you don't have one.This will give you alot of imfo you will need.I don't think the 2 mufflers caused the cat clogging if it is but it has restricted the exhaust and loss of h.p. You need to get a dwell meter thay don't cost alot. Mine was about $29 and worth it when you need to adjust dwell and RPM. There is a way(basic adjustment) (1) Disconnect one of the injector lines from the fuel distributor.(2) Operate the fuel pump by pulling the fuel pump relay (under dash by your left knee) green relay.(3)With the key off use a jumper wire between #30(red) and #87(yellow/red) to opperate the fuel pump and with a allenwrench turn clockwise untill fuel comes out,then turn counterclockwise 1 half a turn and thats a basic adj.JUST BE CAREFULL WITH GAS COMING OUT.I think the dwell meter is better and more accurate and safer.Well if you checked all the things I mentioned you may be looking at buying a new cat.OUCH,Don't tell anyone but when I saw the cost of replacing mine I removed the cat and bought a pipe for around $55(no state inspection where Ilive) and if I have to replace it I will have to bite the bullet. Charlie