Yes, it is another one of those posts...

Need some help since I failed my pre-test as a gross polluter. Truck is a 97 Ram 1500 5.2L (318) w/ 116,500 miles. No EGR. Elk Grove, so has dyno testing.

Results:

15 mph
%CO2=13.3
%O2=1.4
HC=102 PASS barely
CO%=0.84 FAIL (0.62 is PASS)
NO=2180 FAIL AS GROSS POLLUTER (999 is PASS)

25 mph
%CO2=13.3
%O2=1.4
HC=100 FAIL (95 is PASS)
CO%=0.81 PASS
NO=2078 FAIL AS GROSS POLLUTER (859 is PASS)

Going right now for a new cat converter since it used to rattle but stopped. O2 sensors are new (about 10-15k on them). MSD 6A iginition and Blaster coil are being disabled as well. Going back to factory if possible. Oil changed last night, new air filter, breather cap, PCV as well.

At least the guy said he would do a manual retest for $10 when I come back.

Any other ideas to what the problem(s) could would be nice.

Thanks

Just got back from the exhaust shop. The cat was toast. What catalyst was left was totally melted. Glad I have a straight through muffler....

I know I am running really rich, too much gas getting to the cat and burning it up. Just need to figure out how to fix it. Damn computer controls...

If those specs are with a toatsed cat, your junk is running really clean!
a cat will make those problems go away,
do you have any exhaust leaks? it sure looks like it

With no EGR, the engine relies on the 3-way catalyst to reduce NO. It is also running rich and/or missing, so maybe check for a stuck injector? Either way, a new and funcitoning catalyst should help a bunch.

Well the PCM is not spitting out any codes. I just tested the the MAP, IAT, TPS and injectors and they are all within spec.

The exhaust manifolds were just replaced with used but perfect OEM replacements and I can not hear/feel any leaks. I just rechecked the manifold bolts they are at spec.

I also just switched back to the factory coil and bypassed my MSD 6A.

Have you had it retested after the new cat was put in?

Not yet, I go back Friday morning for pre-test inspection.

Oh what the hell, might as well change the plugs before the test.

Well after getting a new cat installed (the old had almost no catalyst left and what was there was melted into one big clump) and bypassing my MSD and going factory ignition I passed smog....

New Results:

15 mph
%CO2=14.7
%O2=0.5
HC=56
CO%=0.14
NO=268

25 mph
%CO2=14.4
%O2=0.5
HC=20
CO%=0.01
NO=186

Didn't realize that a cat actually did change emissions so much when the motor is not running at optimum.