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Discussion Starter #1 (Edited)
One fail was the Fuel Evaporative Controls or fuel system. Any tips on where to look for fuel system leaks? EVAP passed 2 years ago, so this one is new.

2 years ago, with a new cat and a freshly rebuilt engine and carb, I barely passed NOx, but passed HC and CO with flying colors.

This year, after replacing the plugs, rotor and cap. as well as the EGR balance hose, I failed NOx at 15 mph, but passed by a mile at 25 mph.

However, I failed the 25 mph CO miserably. All other HC and CO number were much worse than 2 years ago.

I think one issue, maybe the biggest issue, is that it took an hour for the station to get to Sami, and it had cooled down before they tested it. The previous time, I had gotten it good and hot, and it was tested minutes after I pulled in.

Here are the numbers;

Current 15 and 25 mph(2129 and 2571 RPM);
HC 74 104 PPM Max 138 112
CO .92 2.25 % Max 1.00 1.22 (Gross Polluter)
NOx 1021 37 PPM Max 859 738

2 years ago, with a freshly rebuilt engine and carb, and a new cat, my numbers were, at 15 and 25 mph(1,992 and 2,419 RPM);
HC 0 10 PPM Max 146 126
CO .00 .01 % Max 1.00 1.22
NOx 806 712 PPM Max 1096 956

Ironically, it would have passed with the limits from 2 years ago on NOx, but the CO is way out.

I am replacing the cat as I know that will solve the CO problems, as well as lower the NOx a bit.

However, I'm guessing that the EGR was not functioning as the FSM indicates that it does not function below 131F and it failed on the first, 15 MPH test. I'm guessing the EGR kicked in for the high speed test as the NOx is so low there.

I would have though that the cat would have lit off by the time the 25mph test had begun, but maybe not. That is a moot point since I am replacing it anyway and will make dead sure the engine is still warmed up next time...
 

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Discussion Starter #2
Found the fuel system leak. It was the little vapor tank on top of the fuel filler. It was cracked. I JB welded it.
 

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Discussion Starter #3
I replaced the cat, made sure the engine was hot when I handed it over for testing, and it blew extremely low HC and CO numbers, similar to 2 years ago, and the NOx was very low for the 15MPH test, 4PPM I think, and in the 400s for the 25MPH test, so Sami is good for 2 more years.

Phew!
 

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I got a 89 geo motor in my 87. Got the smog sticker in the door from the dmv inspector. I think diesel is the way to go no more paying the state.:) Thinking about going with a diesel when it craps out on me but it will be a while being a fresh motor as well. I even got a JA11 hood from Japan shipped in mint condition in the same color.
 
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