I finally passed today. I figured I'll post the rest of what I did in order.
- After changing the O2 sensor, I made some cables from a PC power supply because the pins fit perfectly onto the O2 sensor plug pins. Adjusted the AFM bypass bolt as best as I could.
- I had another test and failed again:
RPM 1758
CO2 14.5%
O2 0.4%
HC 8 ppm (max 95)
CO 0.00% (max 0.58)
NO 1289 ppm (max 795)
RPM 2883
CO2 14.7%
O2 0.1%
HC 3 ppm (max 77)
CO 0.01% (max 0.44)
NO 770 ppm (max 676)
Better than before but not good enough
- I never did find a shop with a gas analyzer to adjust the AFM bypass bolt. The places I talked to only had smog machines that would do a whole test, and no stand alone gas analyzers.
- I plugged the hole in the exhaust pipe next to the O2 sensor as Califred944 suggested. The one that normally houses the CO test pipe. I used a steel ball and the existing bolt there.
- I got this weird intermittent stalling and starting problem all of a sudden and went off trying to debug that. The car would just completely cut off all of a sudden, or have a hard time starting on a few occasions.
- I replaced the DME relay, but I still had the issue
- I measured the fuel pressure, which seemed fine
- I replaced the DME temp sensor
- I tested the AFM on the car as described in Clark's Garage or FRWilk's site, I forget which.
- I cleaned the terminals on the ignition coil, and tested the resistance of the cable to the distributor, which seemed fine.
- I sprayed some electrical parts cleaner on some gnd connections and the reference and speed sensor connections. Tested the resistance of reference and speed sensor plugs.
The last few days have been without stalls.
Today, good news: I finally passed smog. Bad news: I stalled after the smog check and had a hard time starting. Removed the DME relay and plugged it back in, and the car started up fine. Maybe something to do with the connectors in the fuse box being loose, or the wire from the fuse box to the fuel pump or DME.
Anyway, smog results:
RPM 1774
CO2 14.5%
O2 0.1%
HC 71 ppm (max 95)
CO 0.26% (max 0.58)
NO 272 ppm (max 795)
RPM 2838
CO2 14.3%
O2 0.0%
HC 48 ppm (max 77)
CO 0.23% (max 0.44)
NO 522 ppm (max 676)
As seen above, HC and CO went up quite a lot but NO came down.