Dash Tacho Wire A1

[fixkick]

had some luck. 
replaced brown wire and it seems to idle. also, IAC wire was bad so I fixed it an now it idles. Not getting any DTC codes. 

However its running very very rich:
The car has no CAT, and hole in pipe right before muffler. 
Also th EGR bark nipple is broken off.
I assume with no backpressure the EGR system isnt working properly which could be giving me this rich situation.

Think the lack of CAT and subsequent EGR issue is throwing my car into failsafe mode making it run rich?
I'm not getting code 41 anymore, but its still  rich and smokey. Compression is also 150 cold so dont think its rings.

injector misfiring is super bad,  the ECU is doing that and is wrong, only why  matters
the EGR is dead now both ways, no CAT and no bark tube, means EGR will never ever open again, and must be closed now and if is closed not cause rich fueling
after all the EGR is never used EVER at  IDLE nor is it used at WOT wide open throttle. SO those are not rich even on day1 new car. EGR is for cruising and NOX reduction only.
but if  the  injectors misfires the ECU  will go mad due to huge vacuum fluctuations at the Map SENSOR.
are your ECU caps good, if not the injector will misfire so will spark or as we know all code 41s is spark misfire and 41s cut fuel  at the injector, so that 41s would  cause the injector to cut fast.
if 41s, 42s are gone the injector must not misfire,  or CAps IN ecu ARE BAD. (NO CMP ERRORS CAM SENSOR IN DISTRIB.)

150 IS GOOD PRESSURE, COLD OR WARM ENGINE,

So what causes smoke black if no DTC errors and not  in limphome mode.
in order.
1:way too high fuel pressure, saw one old care that had a siillly huge fuel pump outiside  the tank off a FORD Crown Victoria, and it was so powerful it over loaded the  FPR all the time
like garden hose to a  fire Hydrant, wild..

2: gross misfiring,
3: map sensor reads wrong key on no start and key on idle voltage out, of MAP seen on my map table , see map page in fixkick.com type map there.
4: vacuum is wrong 19inches HG. at idle and steady not bouncing like mad. ever and for sure not while idling at 800rpm ISC working and controlling idle hot engine.

5:
The ECU may need new CAPS (called a ReCAP job) everyone Ive seen needed, a simple job if old school soldering is easy for or others.
engine not at 180f coolant,
6:
ECT not at 300 ohms hot but way higher ohm ,the ECU adds lots of fuel (too much for any hot engine)

Thanks Kick. I put in another ECU, new injector o rings, new FPR. The injector is firing pretty well. NO DLC CODES. 
Im getting closer to finding the culprit - so my cold idle was very high and it was surging, then when warm it idled back down and then the rich symptoms started. While running, I unplugged the ISC harness, and then it seemed to idle better - and NO MORE SMOKE.  GREAT news !
The resistance of the ISC is 12.3 ohms and the voltage is withing range. good and voltage will be 1/2 of alternator/battery voltage, or 7vdc using only analog needle voltmeter (if not turn the bleed screw (hot engine) to 7vdc on the needle.
 The ISC looks new.
 I tried adjusting the air bleed screw on the throttle body as well as the adjustment screw on the ISC valve. 


I was able to get the idle down, no more surging, but its still running a tad rich.
ISC 5mm hex screw is factory set, but can be set to just lightly closed , just landing there to the seat inside.
For the ISC adjustment screw, I turned in CCW, then blew air into it while turning it CW until I could barely blow air into it, then just half a turn more CW.  I think it was turned out CCW too much which is why it was surging so much which is why it doesnt surge anymore. 
surging is the ECU doing that to the ISC< due to 800 RPM can not be attained, (ECU + ISC servo actions that)
in fact all air leaks in to the plenum can cause surging if 800 can not be attained, ECU controls that. only. at IAC. hot engine, cold is iAC controls all thermal.


For the TB air bleed screw - I turned it in clockwise all the way, and then half a turn out until hot idle is set at 800rpm. Now what happens is: 

• When cold, it idles at 2500rpm, then it takes about 5 minutes of driving to slowly come down to 1000rpm
  
• After 15 min of driving it fall even lower now, about 500rpm - so if I just the TB air bleed screw to adjust it now to 800rpm, I think when cold it will idle way too high now. So cold is too high of rpm, and stays high for too long if hot is 800rpm.   (the IAC is 100% thermal and the RPM is based on water temps the colder water is the higher cold RPM is all by the actions of the IAC WAX PELLET INSIDE, IT.
  

My plans: I ordered the TB throttle body gasket kit from Rockauto. I will be removing the throttle body and then cleaning the IAC and ISC ports and the TB air bleed port with carb cleaner. I will replace the base gasket using the correct "91+" in the set which you have photos for.  THIS IS A GREAT IDEA  AND THE BOTTOM GASKET MUST BLOCK THOSE 5 Tiny holes.
While the throttle body is off, I will also re-calibrate TPS. that is the best way and TV set to 0.0005" butterfly gap to 99.9% closed, FIRST (TV stop screw inspection first )
I will then do a rough ISC calibration    using the method you described where I turn the screw CW until the valve just seats (very minimal air flow) and then a half turn more. I will then re attach everything and then adjust the TB air bleed screw until fully hot idle is 800rpm. 
and ISC set to 7vdc, use a voltmeter, with real needle, even a $10 meter like that at walmart.  this needle tick averages the 200 Hz square wave signal on the ISC pins. 7vdc is it.

My stat and stat gasket and ECT sensor is new so that shouldnt be the problem. 
One side question: I did install a new radiator cap. The imprint says "0.9" (0.9 bar is 90% of 14.7 psi atmospheric pressure ) and is spec.
which I assume is 13 PSI.
My 96 16 valve kick has a "1.1" 16PSI cap. Do you think the pressure rating on the cap is too low?   no the difference is marginal. and the cap is crude, it is only a ball park number.


Thank You
Sina

yes get a needle analog meter like this. volts DC.


https://www.walmart.com/ip/DC-AC-1000V-V...hbdg=L1700


hot engine, 180f water
connect meter to ISC wire pair.
battery is at 14.7 or 13.3vdc (the lower number is float charge , higher number is fast charging, divide by 2.
7vdc is good goal at ISC (use the 10vdc scale or if your meter is 20vdc use that) DC. not AC.
turn the bleed down until it reaches 7vdc,  and that is now 50% duty cycle and even at high altitude the ISC works. right.  and 800 RPM held solid.

do this all after fiddling with 6mm hex screw on isc, set it for just lightly closed engine off. just kissing the rubber ringed seat inside.
if the  seat leaks a bet that is ok the bleed screw will correct that error easy.

btw your doing GREAT !
good luck to you and your little Sidekick.