What did you car fail emissions on?
I tried everything to get ym car to pass... the cats were good / clean, new spark plugs, no vac leaks, new o2 sensors but still kept failing on NOx.
I unplugged the SPOUT connector and it passed. Unplugging the SPOUT retards the timing 10 degrees IIRC by bypassing the cam sensor, and synchs the timing with the crank sensor if I got it right.
By the way, is your check engine light still on, and does your car still stall / tach dies? that might be part of your problem if your cam sensors not working right as suggested in the other post.
Edit: as far as the rattle, any chance you could post a sound clip? and did you check the basic stuff, like bang on the exhaist to check for loose heat shields? any idea on the location of the rattle?