So, after a shit-ton of money, countless tests, much swearing and assistance from a number of members, SHE PASSED!!!!! I feel like I've just won the freakin lottery.
Here's the numbers...
HC - .5 allow / .4125 reading (.2965 avg)
CO - 9.32 allow / 1.2749 reading (4.6090 avg)
NOx - 1.24 allow / 0.1594 reading (0.7309 avg)
Work done:
New cat (thnx Tommy
, new O2, 2G 450cc injectors (thnx Kevin
, unmolested 1G MAF (thnx Tommy
, base timing @ +5 (thnx Jovan
, zero'd AFC, Chevron 94, EGR in place, pcv in place.
The high HC count is likely due to oil in the intake from the valve-cover breather & leaking turbo seals. breather's been resolved, but turbo's yet to be rebuilt.
Hopefully this thread helps someone else when their DSM decides to be difficult at aircare time.