Sorry for the loooooooooong overdue update. I wanted to ensure I had the right information before I provided a reply regarding the emissions inspection.
Here is the update:
During the installation of the headers by 5Star, they did not plug in the rear O2 sensors. As you guys know, the rear )2 sensor needs the supplied wire harness extension piece to be able to plug it in. This was in the bed of the truck in a bag with the locking bolts that they supposedly tried and didn't work. They did call and ask about the extension wire, but never told me they couldn't find it or that they never installed it….
So the truck was running without the rear O2 sensor plugged in on the 91 performance tune. From what I understand, the tune doesn’t use the rear O2 sensor and tricks (not sure of the right term) the computer module as if they are in working order. Also, during the installation, the battery is disconnected.
I took the truck in for inspection; unaware of the disconnected O2 sensor and that the disconnected batter would have reset the readiness codes. I had driven about 1000 miles from NC to Pittsburgh, where I was having the inspection completed. The truck was on 91 performance tune.
Before emissions testing can be completed for inspection, the vehicle readiness codes need to be set to “Ready” status. If your battery had been disconnected, the codes will be reset to "not ready” status. From what I understand, the 5star tune doesn't affect theses codes. There is a specific driving sequence that you have to do to get them to be in a "ready" status. It had nothing to do with how many miles you drive, but how you drive those miles.
My wife and I drove around for two days before Christmas with the scan tool connected to the truck and they kept saying "not ready". We had over 100 miles on the truck. RW started looking on the internet for possible solutions; she then found that some people had success following an obdii drive cycle for Ford trucks. Once we found enough highway to perform the drive cycle it started to clear the codes as we drove the way it recommended.
Things like speed up with 1/2 throttle up to 40 MPH, drive for 5 miles, coast down to 20 MPH with out making any sharp turns or hitting the brakes. Then speed up to 60 MPH with 3/4 throttle and drive for 5 more miles, then coast down to 20 MPH without making any sharp turns or hitting the brakes. You know how hard that is to do??? Lol…
Once the codes all said “pass” I took it in for PA state emissions and it passed. Afterwards, I put the 91 performance tune back on. Was glad to get the stock tune off and back to the performance.
Here is the drive cycle:
Ford Motor Company Driving Cycle
It was the only way I was able to reset the readiness codes to ready status after the installation and get the truck to pass emissions inspection.
