Thanks Jack, Scott & Everyone!!!

I'll go ahead & install the new cat & O2 sensor.

& I need to check the timing, fer sure,
but actually, I was quite surprised it didn't pass
The engine is a VW rebuild with 20K on it
It Sure runs Good !!!

But, I too am leaning towards the Air Flow Meter at this point.
I've got a spare & I think I'll stick it on just for grins
see how it runs,
& get the bus re checked !

Is it OK to spray the AFM with carb cleaner in a can?

Thanks again !!!!
John C...

-------------- Original message --------------
From: Scott Daniel - Turbovans <scottdaniel@TURBOVANS.COM>

> good advice on not using premium.
> also............check throttle switch adjustment.
> get the van as hot as you can get it for the sniff test.
> I've not tried it, but have read that multi-electrode spark plugs can help.
> was timing mentioned or checked ?
>
> ----- Original Message -----
> From: "Jack R."
> To:
> Sent: Saturday, October 18, 2008 3:29 PM
> Subject: Re: 2.1 Syncro; Failed Emissions "Say it isnt so Joe:" :o)
>
>
> > John,
> >
> > Stick with Regular Gas... premium will make things worse, as the motor was
> > designed to run on Regular.
> >
> > A new muffler will NOT effect emission, leaks before the CAT / O2 will
> > however. After the CAT, no effect on emissions.
> >
> > Check ALL your vacuum hoses for tight and proper fit.
> >
> > Check for air leaks by the intake, and the AFM.
> >
> > If all is fine, then adjusting the AFM, or trying a near by friend's
> > (borrow
> > the AFM off another Vanagon which passed recently).
> >
> > Have you done a "leak down" to make sure you have full compression at each
> > cly? When you changed the plugs did they all look the same?
> >
> > Check all your electrical sensors, clean and re-connect using Di-Electric
> > grease. Clean all your ground straps.
> >
> > Run a tank full of Techron (use the 20 gal concentration on a full tank).
> > http://www.chevron.com/products/ourfuels/prodserv/additives/tcp.aspx
> >
> >
> > The new CAT and o2 can't hurt, but not sure how much it will help.
> >
> > My guess is a vacuum leak, or bad AFM...
> >
> > If all else fails, move to Michigan, we don't do emission testing any
> > longer
> > (It was a big racket, and studies show very little impact to air quality,
> > due to the majority of cars on the road pass).
> >
> > Best of luck to you!!!
> >
> > Jack R.
> > 84 Westy Wolfie, with a 2.1L WBX. (owned since 1987)
> > N. of Detroit.
> >
> > -----Original Message-----
> > From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
> > John C...
> > Sent: Saturday, October 18, 2008 5:03 PM
> > To: vanagon@GERRY.VANAGON.COM
> > Subject: 2.1 Syncro; Failed Emissions "Say it isnt so Joe:" :o)
> >
> > Hi All,
> >
> > Yup, my new (to me) 87 Syncro 2.1 Failed Emissions ( for the 3rd time) !!!
> >
> > Readings: ( and the third test was Way worse than the first two ) !!!
> >
> > What I did between the 2nd test & the 3rd test
> > was to get the bus out on the freeway
> > & hit it hard for about 50 miles.
> > Kicked the cat many times
> > ran out the gas & put premium in it.
> > but readings got worse ???
> >
> > RPM: 991 %CO2: 11.8 %O2: 3.3 HC: 788 CO(%): 1.53 FAIL
> >
> > RPM: 2511 %CO2: 13.5 %O2: 1.6 HC: 203 CO(%): .88 PASS
> >
> > I've changed oil (with 1qt Marvel), filter, air filter.
> > Plugs, plug wires, rotor, cap
> >
> > I now have an O2 sensor, & Cat on the way.
> >
> > My question is;
> > Will the old muffler affect Emissions?
> > Should it be replaced as well?
> >
> > Bus runs quiet enough & I'm going to put a subbie in soon.
> >
> > What can I do to the MAFM? (clean? adjust somehow?)
> > Timing? (retard)?
> >
> > Any & all help much appreciated !!!
> >
> > thanks,
> > John C...