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2008 997 C4S fails emmissions test and noise test

E

EuroDriver

New member
We brought over, from the USA, a 997 C4S with Evoms intake, AWE cats and muffler, and GIAC software.

The VOSA IVA test had the following failures

Emissions test the Lambda readings were 1.05 and 1.08 when the allowable limit is 1.03

A noise test was done at 4,850 rpm which produced a noise level of 101db, 2 db over the limit of 99db

Does anyone have any relevant experience or helpful information ? I hate having to remove all the parts . .
 
If that 99db limit is correct, how does Porsche get the GT3's to pass such a test? My 997S with standard set up, always recorded 99db-100db static test at track days. I would make sure that the test was carried out with the engine at full operating temperatures to ensure it was not running rich when cold. Also get the diagnostics read to verify if the high lamda levels are actually in fault. A faulty coil pack may also be misfiring causing unburnt fuel into the exhaust system.
 
ORIGINAL: EuroDriver

We brought over, from the USA, a 997 C4S with Evoms intake, AWE cats and muffler, and GIAC software.

The VOSA IVA test had the following failures

Emissions test the Lambda readings were 1.05 and 1.08 when the allowable limit is 1.03

A noise test was done at 4,850 rpm which produced a noise level of 101db, 2 db over the limit of 99db

Does anyone have any relevant experience or helpful information ? I hate having to remove all the parts . .
Click to expand...

Having just imported our two Porsche cars into the UK; one of which has a Softronic intake and flash it appears that your testing centre didn't accept the 'California Emissions' sticker as proof of compliance. Perhaps not having a stock exhaust made them wary and they measured everything. My exhaust is the PSE and I can assure you I did not run it in loud mode!!!

I hear what you say about the removal of parts, however, to pass the test you are probably going to do some work. Do you still have the stock exhaust? I also think you may have to return the DME to stock, I believe the GIAC software allows this.

Remember what you present for the test doesn't necessarily mean you have to leave it like this, but beware the MOT for cars over 3 years old, no noise test but it includes an emissions test much the same as the DMV.

Good luck
 

ORIGINAL: EuroDriver

We brought over, from the USA, a 997 C4S with Evoms intake, AWE cats and muffler, and GIAC software.

The VOSA IVA test had the following failures

Emissions test the Lambda readings were 1.05 and 1.08 when the allowable limit is 1.03

A noise test was done at 4,850 rpm which produced a noise level of 101db, 2 db over the limit of 99db

Does anyone have any relevant experience or helpful information ?  I hate having to remove all the parts .  .
Click to expand...

EVOMS intake is widely used over here so shouldn't be contributing significantly to the problem. I have heard that the AWE systems are very loud and am not sure if they are used over here, I am sure some tuning centers use the GIAC chips.

As per previous post - if you have a stock exhaust that might help to get thought the initial test. Doesn't mean you can't swap back to a louder exhaust. But you want to find out what's causing the higher emissions, as when you get to MOT that will be a problem (3+ years old).

Fuel over here tends to be 95 to 99 RON versus a much lower 91 -95 in the US. Silly question but have you had the chip parameters adjusted for UK fuels? Just an idle thought that this might be contributing to your emissions. If your heavily optimized for lower RON fuel that might effect whats happening at the test.
 
The trouble with a lot of aftermarket tuning equipment is that it doesnt carry a TUV certificate of approval. TUV certification is awarded to a tuner or supplier when they are able to demonstrate the part meets or exceeds OEM specification and complies with EU and German law in terms of construction, safety and pollution. Since the car is a german manufacturer it needs to have OEM or TUV approved parts to be considered compliant to manufacturer and therefore european spec. As soon as a car is modified , it has the potential to have emissions , be they noise or pollutant , that no longer meet the manufacturer and type approval set down by EU legislation. As such , the car is I suggest subjected to a type approval test where all the parameters are checked. Had you imported a standard car you may not have had these additional tests.
As Nick suggests you need to go back to GIAC to see if they can reflash your ECU for European RON values as the US/ UK country coding (which would have taken this into account) on the original engine ECU is bypassed by the GIAC chip. The other reason for an emissions fail may be the sport cats , particularly if the secondary air pump and its control have been disabled as a result of the modifications.

There are a number of cayman owners running the softronic remap over here in the UK , i'm not sure how many have cars old enough to require an MOT or the results thereof. This may be another alternative to the GIAC software if you still require a tuned engine.

The lambda reading being out of limits on its own without any other parameters can suggest a leak in the exhaust system allowing air to weaken the lambda reading making it high. I had a similar failure when leaving a small gap in the sleeve between the rear silencers on my boxster.
 
ORIGINAL: okellyt

Fuel over here tends to be 95 to 99 RON versus a much lower 91 -95 in the US. Silly question but have you had the chip parameters adjusted for UK fuels? Just an idle thought that this might be contributing to your emissions. If your heavily optimized for lower RON fuel that might effect whats happening at the test.
Click to expand...

Be careful trying to compare UK to US fuel grades the 'numbers' are not like for like (See link below)

http://en.wikipedia.org/wiki/Octane_rating

btw the US emissions are way more sticker than the EU ones, and Porsche produce two versions of the DME software; LEV (Low Emission Vehicle) and the EU version. All US Porsche's pass the stricter California Emissions standards.

Even in the event of running lower octane fuel the DME 'Knock' sensor compensates for this and retards the ignition.

I will stick with my earlier sugestion, re-flash the DME to stock and remove the AWE Exhaust system, pass the test then re-mod the car.


 
Many Thanks for all of the comment and advice.

Our next test is to put the car into a workshop that has PWIS and emmissions testing equipment.

We are going to compare the lambda readings [before cat], [after cat] and [exhaust pipe sniffer lambda reading] We will also check the MAF sensor calibration

What I did not say in the original post was that the car was flooded up to its axles on the dockside in Newark NJ during the process of being shipped over ! The main wiring loom was replaced, new motors and seat controls, new carpets and newleather seat covers and 2 months in the shop.

After the UK dealer rebuild there were no ECU fault codes, but no emmissions test was done until the IVA.

We are going to try wrapping the headers and mufflers with heat wrap to see if we can bring the noise down by 2 db

Mechanics with a German Porsche dealer think the connectors to the Lambda sensors may have become a bit corroded during the flooding.
 
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