UPDATE
My long automotive nightmare has ended. I passed the MD emissions test on my 10th attempt. I want to thank DC Scotty for originally suggesting that I try air injection.
After testing a couple of other things, like Calum's VE tune instead of JWT's and richening up my light throttle mixtures, I finally tested with the IAV installed and working. Here are the setup details:
- Back to original JWT tune from my first test.
- AIV from 1991 SE-R retrofitted to VE using an early HS header that I had in the basement.
- Installed my old copper plugs NGK BKR6E-N gapped at 0.034" and took out the Iridium plugs.
- Timing set at 12* BTDC (normally at 15*)
I connected the AIV vacuum tube (which originally comes from a solenoid and allows the ECU to activate the AIV under certain conditions) directly to a fitting on the intake manifold on the engine side of the throttle body. So the AIV was activated all the time. This did not cause drivability problems or backfires. However, I did not run the car this way for extended periods of time -- just for testing. The lower hose from the AIV was attached to the brass tubing from the header, and I routed the top AIV hose through the little black noise reduction box and then over by the battery where I secured it with a cable tie and affixed a little filter to it. The AIV itself was attached to the head near it's normal position by a single brave bolt.
Here are the results of the emissions test:
..................State Limit..........W/O AIV.............With AIV
HC..................1.0....................1.6.... ................0.8
CO................20.0..................16.8...... .............11.9
NOX................2.2...................1.8...... ...............1.2
I test again in 14 months, but now I have a better idea of how to pass.
Thanks to everyone who tried to help.
Billc