Hello everyone (New kid on the block)
I brought my tracker in for insp. I was not worried cause that little sucker runs mint. Great gas mileage,no smoke,new plugs,wires,cap rotor,and air filter. T belt at 70k. Now has 140k on it.
FYI, here are the test #s
Veh. reading HC 0.31 gpm CO 3.29 gpm NOx 2.17 gpm
Test limits     HC 0.80 gpm CO 15.0 gpm NOx 2.00 gpm

The engine lite was not on when I took it in. Strange thing is, while driving home the lite came on. Does a bad cat come up on the codes, or did something else say see ya?

Thanks in advance
Frank

The only way a Cat shows is if there is an O2 sensor
behind it, NOX is a result of the EGR not working, at
least not all the way working, clean the EGR and test
again, also retard the timing to the stock spec, or a
degree or 2 more if it's right on now.

NOX is formed when combustion temps are too high,
that's why they add some exhaust, it slows the burn
so it doesn't get as hot, same goes for the timing, did
they check the timing? they should you know, I would
pitch a fit if they didn't and want to charg for a retest

Thanks Wildgoody

I was leaning towards the EGR. Someone else kept telling me it has to be the cat. Don,t like changing parts with no results. I will ask about timing check. They never offerd that info. So I would have to say no.

Thanks for the info. Will post back with results.

Frank

Thourghly clean the EGR system. A super high NOX will indicate the need for a new cat. I did EVERYTHING then replaced the cat and passed with flying colors. 

Thats two for the EGR system. Works for me. Can't work on it till friday. Will keep you posted.
Thanks Guys
Frank

Here's a great thread on cleaning the very common EGR problem.

http://bbs.zuwharrie.com/content/topic,27769.0.html

First off. unciv. that was a great thread. The windshield wiper was the best remedy I have seen in a long time. The only thing I did different was to use wd 40 instead of carb. cleaner. It helped make it slide through easier. I then backed it up with compressed air. the entire EGR system is now apart and I see what i think is a Vacuum line going to nowhere. I have a Haynes book that sux for FI. Maybe someone can help me out. 95 Geo tracker 1.6 16v FI, 5 speed. If you are looking straight at the motor. On the rear left hand side of the head below the EGR modulator. Should there be a tube coming out of the head to connect to this vacuum line? The reason I ask, there is a hole on the left rear of the head just below the distributor that looks awful clean and this just goes nowhere. It doesn't make sense that they would run a hose to nowhere,other than a breather,also below that line tees off. The book shows nothing on this. I don't want to put it back together until I'm sure that line goes nowhere. If I don't make any sense I had a couple of beers while turning the wrench. (It"s good to be the boss.)
TIA
Frank

those 2 lines w/ the T fitting should come form the trans and the other from the T-case they are just breathers but the do have a check valve in them and they should have a little cap on them so nothing gets in. I had a leak in the lines and had to replace them. hopes this helps

Thanks CJ I kinda thought thats what is was. No cap though. At least I know where I'm going with this. Now I can Put It back together. Just to let everyone know the PVC was also bad.
Thanks everyone will let you know how the emission test comes out.
Thanks again to all.
Frank

I have a Haynes book...

There's only one thing to do with this....


Burn it.

Replace it with a Chiltons or FSM

Dave

Yeah I agree. Don"t know what happened to haynes. 8 or 9 years ago they made a good book. NOT ANYMORE!!!!!!!!

Ok guys and dolls. Just finished puting it back together. I just want to say. I thought it was running good before. WRONG!!!! This thing now runs like a raped ape. Caught third like nobodys buisness. In the morning I'm going to see if I can Break the tires loose in 4wd.
awesome!!! Goes in monday for reinsp. Wish me luck. Thanks to all for all your help.
Time to party.

Frank

The partys over. It failed again. NOx only droped by 3/10. While checking things over again i noticed that the switch that controls vacuum to EGR is not working. So EGR was not opening.
So my question is this. What would happen if I bypassed the switch. Given the fact that it will be all warmed up when they insp. it. shouldn't it function as if the switch was working. also changing ECT today. Mabye that will get the switch to work. Any thoughts on this?

Tanks
Frank

Okay I must of had a brain fart. I went back to autozone.com and reread everything. I determined switch was no good. What I didn't do was jack up the truck and spin the rear wheel in order to make the ECM read correctly. Iwent back to the tube for the EGR and pulled it off again. Turns out the inlet to the intake was totaly cloged. when i pulled it off from the start, it was major blocked at the bottom. I cleaned the tube assuming the problem was at the bottom. I took it apart again today,and found the passage to the intake was stoped up solid. What was bothering me was, when I pushed on the EGR diaphram the motor never skiped a beat. I sprayed carb. cleaner up the hole to lossen everything up. followed up with a wire bottle brush. I still felt like it was still blocked. So I shot it with air. It popped like an old pop gun. I drove it for about 30 miles and the CEL never came on. Before it took about 8 miles to turn the light on. I am keeping my fingers crossed for next insp. Wish me luck.

I just want so say. All of you kept me pointed in the right direction.
Bought a cat just on G.P. Now I can take it back. 231$ thankyou.

Frank

IT PASSED!!!!!!!!!!!!! 2.14 down to .30

Thanks again all.

Now does anyone want to but it.

Frank