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[Steveh]

Struggling to pass emissions tried so far changed cat ,sensor, fresh oil ,new plugs ,air filter, blanked off air injection to manifold as nonreturn leaking cant find any vacuum leaks coolant temp sensor seems to be reading right (via chinese "My Naff Code Reader") no fault codes over my 10 days now so full retest Im at a loss what to try now first time readings were CO 0.627 Fail HC 109 pass Lambda 1.047 fail 

[Raeturbo]

That’s very close I’d get a good injector cleaner I there get the engine hot and give it a thrashing and present it at the mot station nice and warm.

[Steveh]

I put a bottle of redex complete system cleanup  with 1/4 tank of fuel and took it for a run it was hot for retests left it running so it didnt cool down tried mot 4 times as i did different things. Seems to be running ok plenty of power no misfires ticks over smooth.

[Raeturbo]

Have you had the timing belt changed recently? Could be a tooth out perhaps?

[Raeturbo]

Slight exhaust leak?

[dave the builder]

I was wandering if one of the valve collets had sprung off ,dropping a valve ,as the headgasket has been done , and you described pulsing ,valves ground etc but if it's tunning ok 
sounds like Addy's 2 ltr problems a few weeks back ,timing is worth checking though
worth reading ...
http://www.omegaowners.com/forum/index.php?topic=145812.0

[Steveh]

I did the timing all the marks were lined up but I will check it thanks. It just seems to be running to well for valve problems or timing ? would it still run one tooth out ?

[dave the builder]

most engines will run one tooth out on the belt
there's also lots of suggestions in Addy's post ,wet thermostat etc  linked above   

[Steveh]

Too be honest Its always been a pain to get through emissions it had a cat before couple of mots before it was sorned so not done many miles  but thought i might as well swap it as the flexi was deteriorating and the cat box had taken a hit on a speed bump by the looks of it.

[Steveh]

Cheers Dave I'l have a look

[dave the builder]

have you tried holding a piece of toilet paper with long nose pliers and seeing if there is any slight exhaust blow from the manifold etc and exhaust joints
IIRC the manifold can crack too on the 4 bangers

[Steveh]

Hi Dave thats a good tip with the toilet paper il try that think il make myself a smoke tester to make sure ive got no vac leaks as well. Its uncanny how similar mine and Addys problems are il be checking my thermostat hope hes ok thread looks like its gone quiet.

[Steveh]

A smoke tester something like this https://youtu.be/fhIW-Crqz8I  i mean.

[iansoutham]

Pattern cat probably that has stopped working.

I used to suffer the same on co mixture on mine (always had good lambda though). In the end I put a 2.2 cat on with a blanking plug where the seconds lambda goes and ended up with 0.03% co.

Ecotec engines will be 0.5-0.6% co without a cat so anything around there points towards the cat not working.

[addy]

Still around.

Left car with MOT place, who got it through emissions. Never asked how I fitted a genuine GM thermostat, as the one fitted seemed to open early.

Have done a vacuum test, shows engine in good condition, so assuming no vac leaks. Done a fuel pressure test which was down slightly, so going to change out the fuel filter recently done for another one. Fuel pressure regulator seems to be working. When vac pipe is removed fuel pressure jumps up. No leak down when left for a while. So maybe with low pressure the fuel is not a mist but slightly droplets from injectors?

Car goes great, pulls even up steep hills and even happy to do national speed limits. Economy is also good.

As said in above reply, only other thing. Is that the cat is from a company I have used before on my vehicles, but it isn't a type approved. So might get a approved one.

Good luck with getting it sorted. If you manage to do it, please let me know. Will be worth finding out what it was.

Car is off the road for now, as some wagon reversed into passenger side front wing. So took out wheel well liner to check for hidden damage. While under there checked on wishbone bushes, as it is pulling to one side when braking. Brake system checks out ok, but wishbone bushes look ready for changing. So got poly bushes for front and normal for back ones. Read that polys give better handling, also the wishbones can be tightened up with wheels in the air. Then got to find someone closer than WIM to do geometry setup, not using manufacturers recommended ones.