Help, looking for emissions experts!!!

[HAWAIIZR-1]

Okay, after a 6 hour round trip in stop and go traffic with no A/C (that is another issue to resolve) I failed my first emissions testing in Japan for imported vehicles. I had to fork over $2500 US or 191,000 yen and only have 3 chances with one used already. If I cannot get this corrected I will suck it up and just look at the Z in the garage under the car cover until I return back to the US in 3 to 5 years.

I am ready to give up, but will not throw in the towel just yet. I have sent an RFI to Marc H to see if there is anything he can do with chip programming, etc. but it might need more than that.

Basically I have the 500 HP package, just owner new rebuild, GVD full porting, stock exhaust manifolds with cats and air pump, B&B exhaust and SGC Stage 1 camshafts (big mistake coming over here to complicate things). The chip has been programmed by Marc, but I don't know all the technical details. Everything is new from plugs, to coils, to wires, injectors, secondaries, vacuum and all components to include PCV system and valves with oil catch can, etc. No fuel additives added.

I heard their standards are strict like CA, but I know squat about emissions or what it takes to pass to fix my issues. During my ownership since 2003, the car has never gone through emission testing since we don't have that in Hawaii.

One note is I did not have exhaust manifold so I was given a set from a 91 and the emissions technician asked me about the two bungs I have plugged after the CAT. On the cat the two O2 sensors are there, but further back there was two more bungs in the pipe and I just plugged them since my 90 had nothing to connect to it or am I missing something?

Anyway, here is the print out:



Here is what they gave me as max allowed:

CO = 2.70 (my reading is 10.076, 4 times more than allowed)

HC = 0.39 (my reading is 0.564, 1.4 times allowed)

NOx = 0.48 (0.310, this is the only one that I passed)

Thanks in advance for sharing your thoughts and experience. I will contact the Manager of Yokosuka Navy Base Auto Crafts Shop since he used to import vehicles or over 20 years and see if he knows a good shop to help fix this.

Craig