Well after $800 at the mechanic I was able to pass emissions down here. Car ran great for about a week, but that seemed to dissolve quickly.

Here is what was replaced:

Fuel Pump
Fuel Filter (a really big'n)
Fuel Pressure Regulator
Spark Plugs (others were fouled while tuning)
New coil for the Pertronix (apparently this wasn't upgraded when the system was installed)

When I got the car back from the shop, she ran like a completely new vehicle. Pulled smooth and hard, a genuine joy to drive. However, as the week went on she started doing this strange surging action. Throttle would be held constant, but the power would let on, then off, rhythmically. This continued for about a day, then instead of just losing a bit of go, she would drop out completely. Eventually she had mot not-go than go and sputtered to a stop. Luckily I was able to nurse her up into a parking area so she wouldn’t be sitting in traffic during the busy Phoenix rush hour. Had a tow truck take my wounded pride back over to the mechanic. An interesting note is that she started right up for him and he was able to pull her into the shop. Seemed to be running smooth as could be.

My guy hasn’t really looked at her yet, but suggested that maybe I just convert her over a Weber due to the age and the...unpredictability of the FI. Megasquirt is another option that I have been considering. Although I’m not sure how much that will end up costing. I do like the efficiency of a FI system, but it would also be nice to have her run reliably. I can do a lot of work myself. Basically had the mechanic get her tuned for emissions so that I would have a good solid base to do my work from.

If you have any suggestions or even ideas that I can give to my mechanic, I am all ears.

In any case, even when she was lurching down the road, she looked good doing it. :-)
--
1994 Volvo 940 n/a Wagon