EGR needs to be vacuum tested. I dont know how to test the o2 sensor. They make special sockets to remove the O2 sensor.

 

Is there a way to tell if either sensor is bad by just looking at it? O2 sensor is a negative, EGR, I don't know. The 1996's didn't have that (un)handy part.

For the oxygen sensor, indeed they can be a pain in the butt to remove.
Heres what I did: 1) Get a torch, and heat up the area around the O2 sensor until its a dull red color. BE CAREFUL. Common sense says fire (torch) and gas/oil/etc do not mix well. 2) You can try using a wrench or socket, but the "head" of my O2 sensor was rounded out from my attempts to remove it, so I used a pipe wrench with 12-inch cheater pipe. It didn't take a lot to break the O2 sensor free. 3) Remove the O2 sensor. Remember, you just heated the sensor up, so if you need to touch it, make sure your wearing good gloves.

I know nothing about EGR systems (aside that it means Exhaust Gas Recirculation), so here's what the 1990 service manual says:


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[IMG]local://upfiles/948/AC82EB2D1A0D4A55B1A075E09151F19D.jpg[/IMG]

 

Any updates to this saga?
Am I crazy but if you love the truck and everything else is good to go.....what is wrong with droping another rebuilt engine in?

 

Got the O2 off with a 1" opened end wrench, wasn't hard to break loose it was just hard to get to and fit a wrench in there. As far as dropping in a new engine i have considered that, but i'd hate to go through all that when the problem could be solved with a $40 O2 sensor. Plus i don't really have the money, time, or knowledge to drop a new engine. i'll probably get a new O2 next week and see what that does and go from there.

 

check your throttle position sensor, if its going bad it could be letting telling the computer to let in too much gas. That just happened in my 2001 and it had the same symptoms yours is showing.

 

Whatever happened with the injector control circuit code. With that code and the fact that you are smelling gas and sooty exhaust it would seem to me that you are getting to much gas in at least one cylinder. Meaning the computer may be holding one or more injectors open by keeping a constant ground instead of flashing on and off. Are any of the plugs soaked with gas when you pull them out?