Sorry for the very delayed update, guys.
Well, I got it to pass. I seafoamed it, and ran a bottle of lucas fuel treatment through the gas. Told the new owner to drive it a few days to let the fuel treatment work, then get it tested again. This was on a Saturday. The following Tuesday he went in and had it tested, and it barely, barely passed. But it passed, so my obligation is finished.
The limit is 2.0, and the old ***** squeaked out a 1.94, LOL. If I had fathomed that $15 of additives would have made it pass, then I wouldn't have shelled out the scrilla for a new EGR valve...but what can you do? Thanks to everyone for all the help.
Obviously something is off still, since it came so close to failing again. I'll probably never know what the problem actually is since the thing runs like a top...I can't figure it out. Oh well, I hope that it gives the new owner many more years of trouble free service.
I miss my Yukon, but my Land Cruiser is quite the beast off road, and the payments are cheaper. Much slower than the Yukon (only 230hp), but the 4.7 V8's are torquey mofos even if they aren't that fast. If the new Biz takes off, I'll be buying a NNBS Tahoe as our company hauler.