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This is related to my 93 p/u in my signature. I have now failed emissions testing 6 times in almost two weeks. Here are my test results from the tests.

HC (Limit 174) CO (Limit 1.96) NO (Limit 1121.0) CO2(no limit)

T1 195.7 .52 654.4 14.3
T2 196.2 .52 638.2 14.28
T3 203.7 .48 628.7 14.31
T4 209.6 .53 593.1 14.25
T5 205.5 .51 651.2 14.15
t6 219.7 .54 679.2 14.21

Test 1 - 3 were all done on the same day Feb 28
Test 4 March 8
Test 5 March 9
Test 6 March 10

Here is what I have done so far

Prior Test 1 - let truck run (parked) for about half an hour. Then drove it for about 20 minutes prior to test

After Test 1 / Prior to Test 2 - ran a seafoam style cleaner through motor, which caused a big cloud of smoke. Then did an oil change. Then drove it for about half an hour, exhaust smelled like gas then went to get tested.

After Test 2 - drove the piss out of the truck, about 200 miles then went to get tested and put dry gas in the tank.

After Test 3 / Prior to Test 4 - Ordered an EGR valve. When it came in installed it and then drove for about 150 miles. Then went to get tested.

After Test 4 - Me and two other people started going over the engine and found a big leak in the intake after the AFM before the intake manifold. I fixed that, re-calibrated computer and noticed a difference in power and how it ran. Ran some more cleaner through the motor and some more smoke came out. Not as much as before. Exhaust still smelled a little like gas

After Test 5 - The same two other people and me went over the motor again and found that the EGR modulator filter was rock solid so we borrowed one from another vehicle. Then we noticed that the truck smelled a lot like gas so we checked the charcoal canister. It was clogged. We blew that out and were eventually able to get air to pass through it. We also checked my plugs. Nothing abnormal other than they were a little white. The air filter was also filthy so I cleaned it (K/N drop in filter). The next day I re-calibrated the computer started the motor and I had white smoke all over the place. I filled it up with 92 octane and I ended up driving it for almost 3 hours between 70 and 75, about 200 miles. I have a lot more power, engine runs smoother, motor idles better, and I have no gas smell in exhaust. Next morning I drive to work (20 minute drive at 35 mph) and when I get there I notice that my exhaust smells like gas again a little bit.

After Test 6 - Failed again with the highest yet in HC. Now I am pissed. Yep my exhaust smells like gas again, what the f#$&??!!!??!!. I order a new charcoal canister and EGR modulator from Toyota.

Here is some more info about my truck:
- my truck has 228,000 miles on it
- 9 months ago replaced my cat and muffler with magnaflow free flow cat and flowmaster 40 muffler and went to 2.25 pipe
- 3 months ago I did a plug, wire, dist cap, and rotor replacement.
- air filter cleaned two days ago.
- fuel pump replaced two years ago.
- same fuel filter as when i bought it 2.5 years ago. I tried to change it, but lines are frozen to filter. Haven't gotten around to dealing with it yet.
- radiator replaced two years ago
- oil change, I run synthetic
- when warm engine idles about rought 500 rpm.
- HG done at 98,000 miles
- I have never changed O2 sensor
- My check engine light is it not on and the bulb does work. I checked.
- I have not bothered to check for codes since above is not on
- I have a snorkel on it and the fan at the e-check does not point at the snorkel
- motor used to run a less than half on the temp gauge. Noticed about 4 -5 months ago now at half
- radiator full and clean
- no oil leaks or drips. I have placed cardboard under it numerous times.
- I do need a quart of oil about once a month and I think that is due to my oil pan seal leaking a little. I dont drop oil but there is the flow by from air on the bottom end which I think is slipping by a little when I am driving
- I can take off my oil fill cap and I engine falters a little, but not much. before I found the intake leak the motor would almost die or die.
- I have removed the ISR and replaced intake tube with stock since boots were leaking.


Here is the kicker I am now driving on expired tags, my birthday was in February, and I need all the help and insight I can get. Does anybody have any ideas, experience, or thoughts that would help me I? could use all the help I can get at this point
 

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masterwacker said:
- same fuel filter as when i bought it 2.5 years ago
- when warm engine idles about rought 500 rpm.
- I have never changed O2 sensor
- I can take off my oil fill cap and I engine falters a little, but not much. before I found the intake leak the motor would almost die or die.
Based on that info, I can suggest the following:

~Test O2 sensor functions and replace as required
~Test air flow sensor functions and replace as required
~Replace your PCV valve
~Replace the fuel filter (however, this doesn't seem to be a related cause)

You keep saying in your comments that the exhaust smells like gas. That tells me your mixture is wrong. Usually two common things cause that, bad air flow sensor and/or bad O2 sensor. I'm certainly leaning toward the latter, but the air flow sensor is definately suspect. Stuck fuel injectors can also flood the engine with fuel, and also contribute to that rough idle problem you mentioned.

There are several other issues going on with the engine too that may be contributing to the problem (like the fuel injectors as mentioned, dirty throttle body, vacuum leak, etc). It just really sounds like the engine hasn't received much maintenance and all these problems are now catching up with you. I'd have a mechanic take a look at it and give you some service recommendations before you start throwing money all over the place like you already have. Some of the other maintenance related problems are just too hard to diagnose without seeing the truck.
 

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Sounds like O2 sensor to me. Seems like they have to be REALLY bad to throw a code. Mine is running a lot better since replacing it.
 

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It's worth checking codes as sometimes they'll throw even if the light only comes on for the blink of an eye.

I'd do the following in addition to that already mentioned:

Compression check; bad compression in any cylinder can cause a miss and incr. HCs
Clean throttle intake with cleaner and brush
Throw in new plugs
Adjust idle in-spec
Make sure timing 5 BTDC with IDL-E2 jumpered
New O2 sensor

If that doesn't do it I'd suspect the high-flow cat is not as efficient as stock. Also at that point would pull injectors and have them tested/cleaned, but you're starting to look at some $ to do that.

I'm in the same high HC boat also... JUST BARELY squeaked by 2 years ago with brand new cat so in June I'm gonna be doing what you are now.
 

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seings how i live in california i have alot of experience with emissions and i have to tell you that the high flow cat does not work that great and assuming its a 22re (?) 500rpm is way too low i think its close to norm for the 3.0 though i would definitely do the o2 sensor those do go bad slowly, and the cat from my experiences cures the hydrocarbon problem, and from all my budget minded attempts at more horsepower cat to no cat made no difference possibly even losing a little on bottom, but thats just my 2 cents i suggest a factory cat and an o2 sensor
 

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Is this a treadmill test or are they just sticking the probe in the tail pipe? In VA we have the treadmill and it is based off of speed. If you have larger tires and have not regeared and your speedometer is off, so will the test. I went through twice before I realized that was the problem. I put the stock tires on and passed. I don't know if it would make much difference for you becuase you are a lot farther away from passing, but every little bit helps.
 

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LOL.... I just assumed 22re! Would be good to know what engine we're working with.
 

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if its a 22r it is supposed to idle around 700-750
 
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