My luck finally ran out on my gutted out catalytic converter. It''s not that I''m not "green" it''s just that I got tired of the cat sounding like it was full of marbles so I emptied it out. (posted pics here someplace)
Here were my emission readings before the cat, O2 sensor, and coolant temp sensor R&R (all items were original and have 208,000 miles on them) and after:

Hydrocarbons (HC) In Grams/Mile: Max Allowed:0.80, 1.18>Fail, after new parts 0.39>Pass
Carbon Monoxide (CO) In Grams/Mile: Max Allowed:12.00, 17.64>Fail, after new parts 1.67> Pass
Oxides Of Nitrogen (NOX) In Grams/Mile: Max Allowed:2.00, 2.23>Fail, after new parts 0.38>Pass

Perhaps you can post your "failed" and "passed" readings? These new parts had 6 miles on them before the re-test.
Here are my part numbers:
Direct fit, Marmont Catalytic Converter #29591 $165.40 Checker Auto
Coolant Temp Sensor, Nehof TS71271 $9.49 Checker Auto
O2 Sensor, Bosch #11027 $20.39 Checker Auto
Total: $211.43 w/tax

Note: Here in Arizona the "maximum allowable" readings are the same for any mileage above 50,000 so having 208,000 made no difference in the specs. There were no trouble codes stored with the old equipment.Edited by: MINICooperS

 

Did you expect it to pass with a gutted cat?

 

I wasn''t sure because not all of the "honeycomb" came out of the cat. Didn''t really plan on keeping the car this long, but $20 tags, $100 insurance and mileage in the high 30''s is hard to give up.

 

Once that cat starts to rattle, its shot and not doing its job.

At least it passes now.

 

So . . . Low,
Where does the "secondary air injection tube attaches to the exhauset manifold"? On a twin cam? I''d like to clean it out.