Ok - I took my time with the repairs -doing one at a time and retesting after each one so I would have a better understanding as to the benefits of each repair
So here are the results after starting with a KA24de tuned according to the Factory Service Manual Specs. and using laptop Conzult software -so before bringing the car to each test it was set to spec. at operating temperature. Also all standard pre Etest work was done–oil change-air filter -pcv tested -fuel injector cleaner -new plugs-Sunoco 94 fuel
-------------------------------------------------------- Test # & repair description
---------------------------------------------- 1 ------------ 3 ----------- 5 --------- 7
------------------------------------------ tuned to — -new BPT — replaced — new
----------------------------------------- FSM spec. - to EGR hose – CAT 1.0 ---- O2
------------------------------------------------------- & eliminate – year old — sensor
------------------------------------------------------- vac. leak ----- used
---- (A)SM2525 — ©urb Idle ------- A ---- C ---- A ---- C ----- A ---- C ----- A ---- C
--------- limit -------- limit
HC ppm – 64 ---------- 200 -------- 106 – 112 – 97 — 80 — 120 — 67 — 64 — 72
CO %---- 0.35 ----------1.00 -------- .73 – .32 – .54 – .11 — .64 — .08 – .13 – .16
NO ppm - 485 ----------N/A ------- 2236 – n/a – 878 – n/a – 782 – n/a – 252 – n/a
RPM ----------------------------------1748 – 691 - 2085 - 774 - 1529 - 730 – 2419 - 751
Note that when the car is tested at higher rpms (test 3 and 7) the results improve . There were 3 additional tests that are not shown reflecting this as well. The FSM testing is generally done at 2000rpm and the Etests at or above 2000 rpm showed better results . To emphasize this point -test #6 (not shown) failed the HC at 1555 rpm and without any change test #7 passed at 2419 rpm (on my request for higher rpm testing)
I am not an expert or a tech. but the results seem straight forward. Hope this helps others.
Regards John