Passed CA Smog!!!

Talk and Tech about turbocharged 924/944/968 cars
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Tom
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dr bob wrote: Sun Aug 11, 2024 11:02 am Congrats on the successful test!

That testing is something I actually miss from my car's time in Cali, something that might surprise or even amuse some folks. Local smog guy at his gas station near a property in OC was a car guy, so every visit for the car was a chance to visit and socialize. Most important was the learnings from the various tests over the decades. Slowly creeping tailpipe NOx offered clues about injectors that needed cleaning, for instance. Maybe extra valuable was his willingness to use the two pre-cat test port pipes in the engine bay, which offers the ability to isolate symptoms to one bank on the V8.

Now, out here in the wilds of central Oregon, I'm not aware of anyone who even offers that simple level of diagnostics, and certainly not for the relatively low test fees in OC. I can add a wideband CO sensor for fuel/air mixture, but unfortunately there's no no similar cheap-and-easy option for HC and NOx.

After living through the ugly times in the L.A. basin and watching the slow but steady improvements in air quality over the decades, I'm still a big fan of testing and compliance. Here, I can regularly get a reminder about 'the good old days' with the windows down at a stoplight. I suspect we are a substantial market for Cali cars that wouldn't pass inspection.
I wonder if eventually smog testing in CA will be limited to OBDII-equipped cars and/or they do away with the dyno test requirements and go back to idle and 2500rpm no-load tests. Either that, or the cost of dyno tests will get to be silly expensive. Over the course of the last 3 smog test cycles, a solid majority of shops around here have stopped running the dyno tests. It's just so much easier and more profitable to run an OBDII scan, issue the certificate, collect $40+, and move on to the next car in 10 minutes or less. My test took a solid 40 minutes in comparison. That, and the number of pre-OBDII cars diminishes every day, making the investment in dyno equipment harder and harder to justify as a shop owner.

On an unrelated note, it feels like private shops figured out some time ago that nit-picking every last wingnut is bad for business these days. The 'visual' component of the test is nothing like it used to be. In the early days of CA smog, they would scour your car and make money by finding ticky-tacky 'visual' problems they could use to bilk money out of you (e.g., I once 'bought' a $10 wingnut; and had to 'tip' a guy $20 for the time he claimed it would take to look up various smog rules). That model seems to have given way to just doing as many cars as quickly as they can -- presumably because shops just can't get away with mischief any longer in our insta-Yelp world.

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cda951
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Tom, I hope you're right. There is a stillborn bill in the CA state house to exempt '83 and older vehicles from the CA smog test (which would of course not help 951 owners), which would be a step in the right direction, but I am not holding my breath. Such a thing is not a priority for most legislators, and anything that does not appear to be "green" (despite being a practical improvement for the ever-shrinking pool of '76-83 CA light vehicle owners and smog shops which are forced to maintain aging equipment) would not be a good look for most of them.

I agree with @dr bob about not being against the CA smog program in general. I must admit that I am biased because it puts food on my table as much of the work I do at my shop is diagnosing and repairing "check engine" light issues to ensure that customer cars (the full spectrum of Porsche/BMW from 1976 to the late 2010s) pass smog.

Stepping back, I also appreciate the reduction of smog in the LA basin and other areas any time I venture south. As seen in my signature, I have a fleet of silly old cars, but keep them in good tune, and those with catalytic converters from the factory all pass CA smog with flying colors, even the junkyard Alfa GTV6, which has recently returned to daily driver duty.
Chris A.
---'86 944 Turbo track rat
---'90 944S2 Cab daily/touring car
---'73 BMW 2002tii road rally car
---'81 Alfa Romeo GTV6 GT car/Copart special
---'99 BMW Z3 Coupe daily driver/dog car
---'74 Jensen-Healey roadster
---other stuff

#12

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Tom
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Fast forward another 2 years and happy to report I passed smog today, but not without some effort.

By way of background, I've been using an aftermarket cat made by DEC, which I bought before my 2018 smog test. It was a direct fit aftermarket cat I've documented in the past -- typical CARB-legal cat with minimal 5 year warranty. I had been preserving it between tests, but did a poor job of that since the last test in '24. Big mistake, since I was also burning chips and beating on the car in general.

Bottom line, it was already 3 years past its warranty period, and pushing the car on this cat seemed to cook it. With the car freshly tuned (new plugs, cap, rotor, oil, O2, etc.) and all my regular pre-test rituals complete, the car failed smog for the first time ever.

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These aftermarket cats just don't seem to last very long sadly (at least compared to the NLA factory originals), but the tech also did the 25mph test in 3rd gear. Whether that was an honest mistake or good for re-testing business, I'll never know. See page 9 of the Smog Check Manual here, which says to use second gear. If you look at posted results across the internet, tests that show ~1700 rpms on the 25mph test (i.e., 3rd gear) consistently show higher NOx compared to cars tested at ~2400 rpms (2nd gear). Lugging it bumps the exhaust temps and NOx. This cat was clearly sick, so it's 50/50 whether it would have passed in second, but PSA: when going for CA smog, make sure the test is done in second gear -- per the state manual -- otherwise you will likely see higher numbers!

Since the cat was low-quality (IMO), old, and weak anyway, I opted to replace the cat rather than call the guy out for using the wrong gear. Unfortunately, I learned in the process that DEC no longer sells the direct fit cats. (They might make you one on request, but I didn't want to wait for that). Since there are no direct-fit, bolt-on CA-legal cats on the market, I opted to reuse the DEC pipes and just cut out the cat and weld in a new one. Turns out only MagnaFlow is currently making a CA-legal cat for the 944, with a choice between one with 2" inlet/outlets or 2.5". I chose the 2" to match the DEC pipes better.

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I opted to take the whole DEC unit out of the car, and brace it up so that I could cut out the cat and replace it without losing the correct orientation of the flanges. The alternative is to weld it in the car, but I'm just not that good of a welder. :) The Magnaflow is also stainless, and had to be welded to the aluminized steel pipes on the DEC, which was a whole other fiasco. After a climb up the learning curve, I ended up getting 309L filler rod, which allows you to TIG weld steel to stainless. Who knew... Resulting welds are not Insta-worthy with titanium rainbows, etc, but they are solid welds that did the trick.

Car passed with good numbers! I will be taking very good care of this cat, and might even buy a spare. If MagnaFlow stops making this cat, there would be literally no available new CA-legal cats for these cars -- at least none I could find that are available to buy right now!

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Worth noting that the new cat cut the 15mph NOx by 43% using the same gear and all other things the same as the first test. At 25mph, the NOx went down by 60%, some portion of which (17%?) was no doubt attributable to running it in the correct gear/rpm.

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blueline
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Glad you made it through the gauntlet but what an ordeal. A 43-page "smog check manual"? Good grief. :wtf:

Hoping that you all will eventually get some level of relief.
Tim
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Tom
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blueline wrote: Thu Jul 09, 2026 4:06 pm Glad you made it through the gauntlet but what an ordeal. A 43-page "smog check manual"? Good grief. :wtf:

Hoping that you all will eventually get some level of relief.
Thanks, it's always a huge relief. I tend to obsess on smog tests, so slightly bummed my perfect track record was disrupted, but just happy it was something relatively easy to fix (though not all that cheap). I would have had it done a week ago, but the day after failing, I smashed the bejesus out of my left index finger in a freak garage door mishap. I may tell that story in an upcoming newsletter... I ended up getting welding mitts (like oven mitts with no fingers) to get this done since I couldn't get my bandaged finger in my good welding gloves (or blast cabinet, etc.) -- so the whole project was kind of a one-hand-tied-behind-my-back exercise... I'd post pictures of the finger, but I think it would violate our terms of service. :sick: :wtf: :sick:

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FWIW - I replaced mine with a 2.5” walker 81128 in 2020 and it passed again in 2022 and 2024, so we will see if it makes it later this year.
I did see that a walker 81328 is a fit, available and is on the CA eod list if magnaflow is nla. Always subject to change I suppose.
Wish me luck - with a 1986, Leno is not going to save me.
1986 951 - Silicon Valley

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Tom
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whalenlg wrote: Fri Jul 10, 2026 6:41 am FWIW - I replaced mine with a 2.5” walker 81128 in 2020 and it passed again in 2022 and 2024, so we will see if it makes it later this year.
I did see that a walker 81328 is a fit, available and is on the CA eod list if magnaflow is nla. Always subject to change I suppose.
Wish me luck - with a 1986, Leno is not going to save me.
Good call on the Walker 81328. It does seem available (and cheaper) so nice to know there's more than one option! Walker is lower quality in my experience (at least if the Walker muffler I got for my Mercedes is a guide), but for carb-legal cats, I'm guessing they all pretty much include the bare minimum to achieve certification. The Walker also appears to have heat shields, which are curiously missing on the MagnaFlow...

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Thom
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Well done Tom.
How much of a pain it seems to be to live in such an area where such old cars need to be smogged. You are a true ambassador of the 951.
'90 944 turbo

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