I have not had these symptoms, but wanted to weigh in on some ideas for you:
- If you purchase a subscription to www.alldatadiy.com, you can learn from the ECM wiring Diagrams which small pins to monitor on the rectangular Diagnostic Connector, mounted on the top of your engine. I would recommend, have the engine at idle, normal temp and with a volt meter, set on DC 1 volt range, sample the two or four O2 Sensor readings. Connect your volt meter red lead to these pins, one at a time, and the black lead to ground on your engine. You want to see each O2 Sensor voltage porpoising slightly above and slightly below half of one volt, while engine is warm and idling. If you have O2 sensor readings that are always above .5vdc, they are indicating RICH mixture in the exhaust, back to your ECM. (Electronic Control Module, Brain, Computer)
Lean exhaust is Low Voltage; below .5vdc. (.2, .3, .1, .4vdc) Lean would indicate a Vacuum Leak.
Rich might indicate a ruptured Fuel Pressure Regulator Diaphragm or blocked air passage at the throttle plate, or Idle Air Control Valve, Bypass air route.
- Because you lack power and have an EGR code, I would also recommend a nice tool, called a Back Pressure Gauge. I bought mine and rarely need it, but it is cost effective, when compared to an innacurrate diagnosis at a local shop. If you buy a Snap On EPV311A Vacuum/Pressure Gauge Set, you remove one O2 Sensor and install this tool. Now you start your engine and simply don't EVER want to see over 3 PSI when at idle or driving on the highway. (Simulate this with pressing the accelerator pedal and raise engine RPM to a similar highway speed.
This will quickly eliminate or condemn the mufflers and catalytic converters. These are suspect for your low power, based on the parts you've recently replaced.
Have you really opened up and inspected your Air Filter? I've seen one car a long time ago, that sucked up a plastic bread bag and reduced airflow across a semi clean air filter to approximately 30% airflow.
I hope this helps~
Andy
The O2 sensors are indicating ~2.25 volts or higher when the engine is warm and running rough - indicating that the fuel is running rich. I put a vacuum gage on the Fuel Modulator inlet and can see that the inlet vacuum is fluctuating up and down in rythm with the engine surging while running rough.
A question is what would cause the engine to run rich and the inlet vacuum to fluctuate?