Hey guys,
Thanks for the replies... To answer the questions:
1) Regarding the AFM: A few months back, I decided to tune the unit per Greg Gordon's instruction manual which discussed bosch injection systems. MADE A HUGE DIFFERENCE... however I did return the car to factory settings before taking it in for inspection.
2) The car does run a little rich with the AFM tuned, so the plugs did have a black cast to them.. which I did take time to clean off before sending it in.
3) As for the cat, I had the whole exhaust system overhauled 3 months ago in prep for inspection as I found a leak forming... The cat was checked at that time and was deemed to be the only part of the exhaust that DIDNT need to be replaced.
4) Regarding Oil consumption... My car will leak oil... (no surprise its an alfa) but strangely enough It doesnt burn any (YET)... I maybe have to top it off once ever month and a half... and this car is my daily driver with at least 300 miles going on her every 7 days.
5) The Fail comes from the hydrocarbon emissions out the tail pipe... so if there is more Carbon monoxide for instance than there should be .. it will fail.
6) Concerning vacuum leaks.. In prep for state inspection I replaced all the intake lines... including the hard to find plenum... which was supplied by a VERY good friend of mine.
7) Coolant temp sensor is within range. I had a posting a while back regarding an engine "bucking" which Alfistosteve was instrumental in helping me solve... included in the diagnosis was testing of the CTS.
So I am stumped... I need the car back, as my only mode of transportation are my Alfas... (scary huh).. Silly me (earlier this summer) decided to be a good brother and give my Truck/SUV to my sister for unlimited use when her car died.... Now I am sweating it out in the humidity which a few years back I wouldnt have cared... but I dont like walking into work looking like I just ran a 10K race
Thanks again guys for the ideas.. its greatly appreciated.
Cheers
Martin.