I had a similar problem with a Cadillac a while ago, couldn't get it to pass the I/M test. turns out when I was driving the car it would misfire 1 time on the entire 10 mile test drive. The 1 misfire was enough to stop the I/M test but not enough to set a misfire code. I think it was the EVAP test I was having problems with. Ended up replacing the spark plug and wire for the cylinder that had the misfire and it passed the I/M test about 1/2 mile into the test drive.
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