1993 3.2l SHO badly failed emissions.

[Ksoder]

Hard to say. Condensation is a byproduct of combustion so it could be water vapor or a mix of that and unburned fuel. Is it still as fuel smell/eye irritating as before? There is still something missing here. Either the cats are not burning off enough of whats left and/or there is too much fuel from injectors or something like that.

If you have proper: fuel delivery, metered air, spark, and timing along with decent catalytic converter function it should get you in the ballpark with maybe only some help needed given the age.

The exhaust smell is the same as before, its not a gasoline smell but rather a very strong exhaust smell... Im looking at replacing my TPS and MAF and my O2 sensors and possibly the Fuel Injectors, because im not sure what else to do

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[Greg Corcoran]

Just so you know, I have personally failed the dyno e-test with brand new cats.

I too failed the dyno emissions test with brand new cats from ShoSource - a can of BG-44 injector cleaner and running through a full tank of name brand gas (cured the hot restart issue too, perhaps cleaned a leaky injector?), New ECT sensor (mine was reading low and keeping the car in 'warm up' but not setting a code or turning on the radiator cooling fan), and then a 20 mile high speed romp right before getting in line at the emissions place and I passed with flying colors.

In your case - a 25 deg rise is a nearly dead cat. Those things should get almost cherry red with as much raw gas as they are seeing.
But first figure out why so much raw gas before replacing them... With everything you've done so far about all that is left:
1. I'd go with a F' upped MAF lying to the ECU; Is it stock? Is it clean inside? Are any of the pins corroded?
2. then suspect multiple leaky injectors, but you should see a hard hot restart too (OR - out on a limb here) - DPO put in oversized injectors and they can't flow low enough at idle/part throttle? did you happen to notice if they were original Ford parts when you had the intake off? Did you run the ODB I through the cylinder balance test? I forget exactly how to do it other than it can be triggered after the KOER diagnostic, but the instructions should be on this site someplace.
3. read fuel pressure at idle, should be ~ 46-48 psig IIRC - Maybe loud fuel pump is some Summit Racing special putting out 60 - 70 psig?

 

[Ksoder]

Alright heres the situation... Monday is the day im getting emissions done because tomorrow my parts are arriving.

O2 sensors
Throttle position sensor
MAF
Possibly injectors

If none of those pass it, im gonna do cats.

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[Ksoder]

Turns out theyre open on the weekends, lets see how this goes

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[Ksoder]

Not quite a pass but we're getting close, how much does pulling the spout do?

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[luigisho]

Hard to say. No hard numbers as everyone's runs a little different at this age. Not 100% sure about the NOX but I think it could get you there.

 

[Ksoder]

How do I remove the Spout connector? (Not going to lie, I have absolutely no idea what it is, what it does, where it is, and how to remove it)

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[luigisho]

https://shoforum.com/index.php?threads/how-to-pull-the-spout-connector-with-pics.56278/page-2

I'm looking for a better picture. Square plug in the wiring rear passenger side of engine. Usually has a gray connector plug. Sometimes white or black. It's really just a plug with metal jumper to complete the circuit.

 

[Ksoder]

So I just find it and unplug the grey thing?

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[luigisho]

Yes. Just do it before anyone sees you pull it. It will retard timing and will be down on power while it is unplugged.

 

[Ksoder]

Its kinda surging now? But were rolling with it

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[luigisho]

Hmmm. I don't recall that being typical as just being weak with the timing being pulled to a set 10 BTDC.

 

[Ksoder]

So freaking close

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[luigisho]

Something is still off. The HC and CO should have been a slam dunk. The NOX is right about where I expected given old posts stated =- 50-70% reductions. Sorry, I hoped you might squeak through.

Was it surging at idle or driving? I know IAC causes surging. You had that off and replaced correct?

 

[Ksoder]

Something is still off. The HC and CO should have been a slam dunk. The NOX is right about where I expected given old posts stated =- 50-70% reductions. Sorry, I hoped you might squeak through.

Was it surging at idle or driving? I know IAC causes surging. You had that off and replaced correct?

I'm ordering cats today and we'll see how it goes

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[luigisho]

I think that surging is not right and you may be throwing money at the wrong place. Maybe.. I wish I had the exact answer

 

[Ksoder]

I think that surging is not right and you may be throwing money at the wrong place. Maybe.. I wish I had the exact answer

I think its just about out of gas, so ill let you know... The surging is brand new to today aftet I pulled the spout connecter

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[Ksoder]

I forgot to tighten the hose clamp after the maf and the hose slipped halfway off so it was sucking in unmetered amounts of air, since it was surging before I tested after I pulled the SPOUT, would it be worth trying again? Its not surging anymore


Im asking would that air leak be messing up my emissions?

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[zak]

Yes. Unmetered air would make it run lean, driving NOx higher.

 

[SHOMON]

I would try it one more time. The unmetered air was not helping the situation. Make sure to take it and beat on it before you go to get it tested too! And still pull the spout connector.