I failed emissions with my new motor, advice?

I have a rebuilt motor with 1000 miles on it, and all new plugs, cap and rotor, etc. and even a new cat. However, I failed the CO test, the limit is 1.2% and I was almost to 6%. I have some ideas. First, I think I may be running rich because my exhaust smells, I have a rough cold idle, and I get bad gas mileage. I also have an A237 roller cam, does this affect emissions? Also, I removed the EGR valve and plugged up the holes, is this whats causing me to fail? My old EGR didn't work anyway and I passed before. So out of all of this, which one do you guys think it is?

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1987 Turbocoupe, black, 5-speed, all options besides leather and moonroof, 198K+ and running strong, 17x9 Chrome Detroit Cobra Rs w/ 255/45/ZR17 Kumho Ecsta Supra 712s, MOMO shift knob and boot, mustang shifter (easier to reach), K&N cone air filter with cold air induction, dynomax super turbo exhaust, brute force clutch, tinted windows, white faced indiglo gauges, 2 12" Rockford Fosgate subs and RF amp, Sony XPlod and Pioneer speakers, Pioneer CD player, painted the faded red molding lines blue, painted interior parts blue, neon dome light, aftermarket foglights, runs great, eats rice for dinner. New motor going in soon.
Wanna see my beast? http://www.cardomain.com/member_pages/vi..._id=314900

Probably a combination of those things, but I'd address the Rich issue first because others have passed with the A237.

--n8

P.S. Did you give it a good warming up before going to get tested?

A few questions -

Did you run codes before and/or after the test?

Is your TPS adjusted correctly?

How old is your O2 sensor?

Have you checked your fuel pressure regulator to ensure that it isn't leaking?

Hope this helps.

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Mike Walsted - NATO member
1986 5-speed TurboCoupe with a few upgrades.

My TPS is set right, I have a new O2 sensor, and I have good fuel pressure. However, I have an old IAC, could that cause any problems?

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1987 Turbocoupe, black, 5-speed, all options besides leather and moonroof, 198K+ and running strong, 17x9 Chrome Detroit Cobra Rs w/ 255/45/ZR17 Kumho Ecsta Supra 712s, MOMO shift knob and boot, mustang shifter (easier to reach), K&N cone air filter with cold air induction, dynomax super turbo exhaust, brute force clutch, tinted windows, white faced indiglo gauges, 2 12" Rockford Fosgate subs and RF amp, Sony XPlod and Pioneer speakers, Pioneer CD player, painted the faded red molding lines blue, painted interior parts blue, neon dome light, aftermarket foglights, runs great, eats rice for dinner. New motor going in soon.
Wanna see my beast? http://www.cardomain.com/member_pages/vi..._id=314900

The A237 idles a little rough but not real bad. I havew never even come close to any emissions limit with the A237. If everything else is working correctly, the cam is a non-issue. Did you throughly warm up the engine before the test, like for at least 25-30 minutes?

Check the FPR for leakage, a different issue than pressure. Take the vacuum line off at the regulator and check for gasoline or the strong smell of gasoline. If either is present the regulator is bad.

The EGR could be part of the problem, but can't say for sure. It will affect mileage.

I had like an hour to warm up before inspection, I even turned off the fan for a little bit, because I know the cat has to get hot. As far as my FPR goes, I had good fuel pressure on the other motor, but I didn't check it on this motor. My exhaust smells funny, like it's running rich or something isn't right. It shouldn't be running rich because I have a new O2 sensor.

My Dads friend who works at Ford said I bought the wrong kind of cat. I just bought a universal dynomax cat, which is a little shorter than stock. He said I need a a dual bed 3-way cat. However, my CO is high, and it seems like the 3-way catalyst is for NOx and the conventional cat is for CO. Therefore, I don't know if I need a different cat or what.

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1987 Turbocoupe, black, 5-speed, all options besides leather and moonroof, 198K+ and running strong, 17x9 Chrome Detroit Cobra Rs w/ 255/45/ZR17 Kumho Ecsta Supra 712s, MOMO shift knob and boot, mustang shifter (easier to reach), K&N cone air filter with cold air induction, dynomax super turbo exhaust, brute force clutch, tinted windows, white faced indiglo gauges, 2 12" Rockford Fosgate subs and RF amp, Sony XPlod and Pioneer speakers, Pioneer CD player, painted the faded red molding lines blue, painted interior parts blue, neon dome light, aftermarket foglights, runs great, eats rice for dinner. New motor going in soon.
Wanna see my beast? http://www.cardomain.com/member_pages/vi..._id=314900