Re: Emissions without EGR valve
Just went through all of this with my 92 Ty. Truck has no EGR and at the time had the original 1992 catalytic converter on it. In metro parts of GA (outside have no emissions testing) you only do the 2 speed idle test as there are no all wheel drive rollers for emissions testing so our trucks are exempt from going on the rollers. Note that the Sy and Ty trucks were NOT on the list of vehicles exempt from roller testing with the sniffer. I had to argue the point and show that the Olds Bravada was one it and we share the same AWD platform. Even then I had to prove it to the guy so he didn't end up with a $500.00 fine. It's called due diligence which he explained that if the state came back to him he had to be able to prove that I showed the truck to be what I said it was. I have an iPhone so I Googled it and showed him the truck on Wikipedia so he could tell the state to do the same if they had an issue.
Anyway, the truck would only pass the high speed idle test with the current cat on it. The low speed test showed about double the HC output allowable. I spent countless hours trying to figure out what it was not knowing the original cat was still on the truck. I just happened to be going through the same thing with my 1994 K1500 Blazer. After replacing everything on the truck but the cat and testing the same (failing) even with a brand new EGR system on it and new O2 sensor among a bunch of other things I did. I replaced the cats on both vehicles and passed no problem. The K1500 was on the rollers and tested flawlessly with the new cat. The Ty also tested perfectly with no EGR with a new cat. The new cat cost me $207.00. Basically my buddy who is a mechanic explained that with a new cat even a poorly running car/truck will pass because the cat catches all the bad stuff before it gets to the sniffer.
He kind of proved this when I replaced every damn thing on the K1500 but the cat and tested exactly the same every time. New: O2 sensor, EGR valve w/new EGR solenoid (cleaned the orifice tube well), 2 cans of Seafoam through it for carbon deposit removal, vacuum lines on top all replaced as I found a couple that were cracked and hardened, I did the plugs and O2 after the Seafoam was done, fresh Mobile One. None of this had any difference on the way the truck ran or tested. Only after the cat did it pass.
My Ty had new plugs, new Taylor wires, new MSD Ignition, new silicone vacuum lines, Seafoam cleaning, fresh Mobile One. It always passed the high speed idle test but would not pass the low speed no matter what..until I did the cat.
As for the visual, they didn't even know what that truck is much less where the EGR valve was. The guy didn't even lift the hood on it as he used the remote sensor to pick up the idle instead of using the thing that clips to the plug wire. He did look for a cat with the mirror, nothing more.
Hope this helps!