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Emissions Failure on 2 year-old Cat. Next Step? HELP!!! 200

Hi Brickers,

Just went for my emissions test on my 1990 240 automatic sedan and failed all three significantly.

Here's the brief background.

The cat on my car is only 2 years-old. I replaced it two years ago after failing the test then. Even with the new cat - which was installed by the dealer, it was still failing. They "said" they put in a new Cat and swapped in a new O2 sensor and claimed that that is how it finally passed. I then had the 02 sensor replaced.

Now, 2 years later, i just had the new test done and the numbers are still the same. very high in all three categories.

I have searched brickboard and identified a few possible culprits - EGR valve (haven't checked it yet), Crack in header pipe (i put a new one in in later 2004), failed CAT (after 2 years???)

Any help from similar E test experiences and solutions?

g

p.s. I am due for a tune-up - last one was about 18 months ago but would that be enough to cause such high results.






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