Catalytic Converter, O2 Sensor & EGR Questions

[fixkick]

My header does have that slot. Also to bring you up to speed where I am at with it now, I got the new cat. It is not melted and is installed properly now. PO removed. Prior to that I checked main cog for damage, replaced the pugs gapped .28 and wires installed properly, I replaced the timing belt but did not move the main and cam crank independently, I set valve lash to .06 but they were only off at .05 and or 0.07 so not much adjustment. The vehicle ran before but will Crank and not start now.

Assuming that all my work is correct could the new cat be the reason for it not starting. Before you answer a little back story. After vehicle would not start I started looking around the engine bay. I found the EGR disconnected from the block with all wires and hoses still connected. It seems that the PO removed the Cat and the EGR. Could the EGR being removed be the reason with the new cat that the vehicle won’t start?

THE EGR REMOVED LEAVES A HUGE HOLE IN THE INTAKE, VERY BAD THAT.
.05" is match book cover thick dont you mean .005" THICK?  or are those metric number?
IS Compression good
spark timing good
does test fuel work (sprayed by hand)'

Yes I meant .005-.007 compression is good and timing good prior. Before there was no cat and EGR was not connected now there is new cat and EGR not connected. Could EGR be the reason why now with the new cat that it is not starting?

what does not connected mean?
there are 3 things (up to)
mounted EGR main, to rear or intake runner #4  (now it cant leak mounted)
one vacuum hose.
and one bark tube to the modulator valve
95 and older has 4th  things the EGRT thermal sensor.


if you have good and fully closed EGR min and leave the vacuum tube not connected but use golf TEE  to plug the vacuum sucking hose,
the EGR is now off line, and out of the pictures
so if spark timing is correct , test fuel will fork,  proving it runs for 3 seconds each spray session. (can of instant start in a can sprayed.)

Not connected as in the vacuum lines and wire was connected but the EGR was not bolted to the engine.

test fuel test,  pass/fail
if compression is ok , engine will run on test fuel, if spark is good.  any gas/petrol engine. (car/truck,lawn mower, outboard motor, motor cycle, and more)  

watch scotty. (he used the IAT sensor hole. )

https://youtu.be/064Ilsz8Fzg?t=31


vw  (no gas tank at all , it runs) like this,  )  V-DUB.



https://www.youtube.com/watch?feature=pl...Pm8#t=141s



https://fixkick.com/sensors/tests/runs-o...-only.html


conditions,

1. CAT NOT MELTED, Yours is not.
   
2. engine compression ok,  180PSI par on 16v
   
3. spark good,
   
4. spark timed.  1,3,4,2 (not wired backward using 8v way) firing at near TDC. 5degrees, BTDC.
   
5. runs on test fuel
   

only exception, flooded engine , spark plugs are new , gapped, 0.028' but when flooded can short,  but easy to dry out,  crank engine at WOT, WOT CUTS FUEL and it dries out.