I have a stock n/a 1987 rx7. The car has over 213,000 miles but engine was supposedly rebuilt 5,000 miles ago. 2 weeks before the test i've done a oil change,oil filter, air filter, fuel filter, new plugs and wires. The first test results were:

15 mph- (HC) meas-114 max 85 (CO) .05 max 0.54 (NO) 114 max 565- FAIL
25 mph- (HC) meas-574 max 67 (CO) 4.88 max 2.15 (NO) 91 max 522- GROSS POLLUTER

I then replaced the main cat with a California magnaflow universal cat. And also an NGK o2 sensor. Not only that i even put Denatured Alcohol in the tank right before the test after i drove the car around for an hour. 5 parts gas 1 part alcohol. Results:

15 mph- (HC) meas- 32 max 85 (CO).03 max .54 (NO) 16 max 565- PASS
25 mph- (HC) meas-639 max 67 (CO) 5.57 max .45 (NO) 0 max 522- GROSS POLLUTER

any ideas on how i can pass it?

 

The results look almost the same, even after changing the cat and 02 sensor. Is the air pump working? If it makes noise, the internal seals can be wasted. I've had that happen to one before. It spit the seals out into the inlet of the ACV (ironically not too different from a blown rotary engine).

The other thing to check is the ACV and related solenoids. The switching (gray plug) and relief solenoids (blue) regulate where the air from the pump goes: exhaust ports, main cat or dumped out the relief pipe. The FSM has some testing procedures for these. If the relief solenoid is keeping the relief valve (inside ACV) open, all of the air from the pump will just be dumped out below the car.

 

Thanks for the response! I will look into that and make sure its all in proper working order.