Ok, first thing is first. I am in the Air Force and have PCSed to Alaska for the next 3 years (not by choice!) and decided to buy a cheap winter car that I could afford to insure and put litle gas into. I bought a 92 Toyota tercel with the 3e-e motor and 4spd manual tranny. I am going to list pretty much all the things the previous owner did to the car. most of this he did because he too failed emissions but eventually passed with flying colors. I can't even get the car on the base until I get it registered so I have to work on it in weather thats usually well below zero in the snow lol. But I don't mind to much I guess! Ok here are parts replaced and most have dates as well.

Spark plugs 2004
oil and filter yesterday
air filter yesterday
new battery yesterday (hard to start at -40 degrees)
exhaust manifold gasket 2005
EGR valve sensor 2005
02 sensor 2005
egr temp sensor was unplugged - for repair it was connected and idle adjusted 2005
EGR valve assy and gasket 2005

lots of headwork...as per reciept
shims
timing belt
more shims
head set
ex valves
boil heads
mag head
grind valve
grind seats
surface head
all in 2004 with over 500 dollar bill it seems

Ok now after all this the car passed emissions with previous owner in 2005 with excellent numbers. Me the other day not so good. Failed for CO and HC. Now before I went car threw a CEL for air temp sensor. Cleaned it and reset ecu with EFI fuse. Did the dumb thing and only waited 30 minutes of idle time (no driving) before testing. ECU for sure had no time to reset. May have even damaged something the morning before trying for about 15 mins to get it boosted off trying over and over to get it to start at -10 degrees. So I failed this test and it was noted I was running rich.

After the test the car ran horrible and would not idle good at all. Drove down highway and idled fine in parking lot waiting on oil change (rarely turn off your car up here bc of cold.) They changed my oil and said they couldn't keep it running (they are good honest people IMO) Every time they puuled PCV valve from the valve cover car would stay running. Replaced PCV valve with no real luck. Turned up my idle ( I can't check it bc I have no tach and I think they guessed at it maybe) and was able to drive it back but feels to idle around 1100rpm or a lil lower. my test numbers are as follows...

HC ppm (limit 750 at idle and 2500rpm) me 1571 idle and 633 2500rpm
CO% (limit 1.00 idle and 2500) me 6.73 idle and 3.17 2500 rpm.
co2 reading 9.8 idle 12.7 at 2500
02 reading 1.74 idle and .70 at 2500 rpm
idle rpm reading was 1054rpm
2500 rpm reading was 2457 rpm
(rpm readings were before the shop changed them.)

Should add that while messing around I removed the TPS and may have gotten it out of adjustment? The car was running pretty **** smooth 5 days ago when I bought it with no CEL at all. Where hsould I start on this? Already ordered a new thermostat and also new Intake Air temp sensor to cure the code of 24. Thanks for ANY help what so ever!

Ok, got a seasonal waiver and drove back to base anyways. Got it in my garage now. I got the code to go away for the ait temp sensonr and got a code 71 I think it was for egr malfunction. Reoved egr valve and it was BAD with carbon build up. Cleaned it back out pretty good. Seafoamed it last night and it idles alot better it seems for now, I for sure need a new gasket where the ext manifold connects to the pipe. It's leakeing badly. STILL smells like car is running very rich. What should I check? This is getting old quick lol.

Your HC and CO numbers are nearly the same as my 1994 Tercel that flew through emissions before the car was parked for 2 years. My car started and drove from where I bought it to our shop and gave up. We pushed it into the building and had to perform a major tune up (and vacuum out the air cleaner) to get it to start.
In your case, you had a stuck EGR, in my case a restricted intake and poor spark. My next step for your car (and mine) is to remove and clean the O2 sensor with either brake cleaner or intake cleaner to remove soot build up. I noticed with mine that when I had the air cleaner unhooked I had 20.5 inches vacuum and connected it was down to 19 inches with a substantial drop in RPM. This leads me to suspect the fuel pressure regulator is stuck due to sitting for so long. Unplugging your PCV does the same thing, lets more air in. My big problem is, with working on other people's vehicles all day, I'm not enthusiastic about working on my own in the evening! Anyway, as I think of things, I'll send along some tips.
Graham.

Ok I am pulling my hair out here...Did a bit of work on the car today as follows...

replaced plugs with new ngk plug gapped to .044 per ngk spec
replaced dist cap
replaced dist rotor button
replaced wires
removed and cleaned o2 sensor with valvoline carb/tb cleaner (it was nasty as hell, I mean BLACK!, sprayed it alot and wiped clean with a rag.
changed oil yet again with mobil1 NON synthetic
replaced oil pan drain plug and seal on plug
adjusted TPS (hope i did it right.) Was reading o volts when i tightened up the screws
removed vsv 1 and adjusted idle (was way high testing center said 1600rpm) and turned throttle screw. Had to guess because i have no tach or access to one right now. Seems to dile decent and warms all the way up to half way.

STILL NO DICE!
It still smells extremely rich even after warming up and there is alot of steam from the exhaust. Oil had a gasoline smel to it but not way to bad. The plugs that came out still had fuel all over them after sitting about 4 hours. I don't know what else to do! There has to be something else! There is one connector that is not connected. It's on the back of the firewall above housing for steering. Maybe for a/c eqp cars? I found absolutely no where for it to go, and it seemed bundled up from factory. What else can I try? My new o2 sensor and cat won't be here till next week and I am going to have to have someone weld the new cat on also. Open to suggestions. Added one bottle of heet and one bottle of some garbage from wall mart that was guaranteed to pass emissions or what ever and am now down to a quarter of a tank. Should add the car still doesn't like the first start of the day or the really cold starts....seems to bog unless I manually hold a steady engine speed for a few seconds!