Catalytic Converter, O2 Sensor & EGR Questions

[fixkick]

SOME of those headers made by Doug thorley are not made now (too few cars on road running I guess)
do you have this slot?


this header  has the magic hidden EGR slot..(and matching new gasket for that , calif CARB certified,  DO YOU have the slot; SOME DO NOT.

THY-716Y-C (or  THY-716Y-SS)   the SS I think is still made, for sure sold.







as you can see this 16v engine had 2 kinds of header,short and long, (calf, and fed)
long tube headers started in CALIF 1992 and later all cards when long.
ending this mess (fails hard) (had after burner plates inside the melt and block exh, flow, yah super bad.. long header is best, and not use  below #1 part

next up CALImini. 

long ago  they made these too  and are very good.

look for the tube   #4 port, seen at rear, here os CALMINI header is EGR fitted. SK703Y-S

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)'

I found that the IG Coil fuse under the dash (15 amp) on drivers side kept popping every time I start the engine. I disconnected the O2 sensor, replaced the fuse and started the sidekick. It fired right up. Now I need to figure out the correlation between the O2 sensor and the coil fuse. The O2 sensor was brand new Bosch unit and I installed it when the I installed the Doug Thorley header. The old O2 that I removed did not pop the fuse so I’m thinking it is the Sensor. How can I troubleshoot this O2 sensor.

Also side not with the EGR valve still out exhaust blew out the back of the block so it tells me the in engine pathways are still open. Also exhaust out the rear tailpipe tells me the used cat I got is not clogged. This info doesn’t really matter to this part of the post it just makes me happy.

when the IG coil fuel blows the CEL lamp goes dead,  ECU is  dead, and spark and injections dead, and test fuel  would  fail  I assumed you checked spark and the lamp, sorry
o2 short deal is super common on all cars for sure this old.
1: wrong O2 used (uses special 4 wire o2)  see link below for the evolution of EGR on this car, COMPLEX it is. changing 6 times  and some with an 02 relay and  shorts there.
2: wired wrong,
3: wires to it melted due to lost suzuki tie back clamps the wires hit header melt and short.
4: bad O2. (not if new and made by BOSCH.)


I have  page covering just them. (varies by year, and Calif/Fed rules) complex. but my charts will tell you what you have.

https://fixkick.com/sensors/OxyGen_senso...ml#unified