Like I said it's a 94 with a manual transmission that I picked up as a daily driver. It wasn't running the best, definitely sluggish and had the typical oil leak at the back of the engine.
so good tore it down and replaced the lower intake and valve cover gaskets. They were nasty. I also replaced the dummy distributor shaft o ring. It was brittle. While I was at it I put in new plugs and wires thinking that is why it was sluggish. I also put in rebuilt injectors since it was apart.
Got it put back together but it's still sluggish and perhaps not running the same as before.
Worried about vacuum leaks I went over it all with starter fluid and propane and found no leaks at all.
I cleaned the sensor that's in the air intake that didn't help.
While it was running I unplugged the map sensor and it died. I'm guessing that's supposed to happen.
So now let me tell you what I observe. It's fluttering as it's running but the tach isn't dropping off. Very sluggish on acceleration and at up to speed. Doesn't seem to go away no matter what rpm or speed. As I sit and rev it up and let off it pops thru the exhaust.
Haven't changed the fuel filter yet, going to do that next. I'm also go to get a fuel pressure gauge and see how the pump is doing.
there's no check engine light so don't know if there's and codes. Going to have to rent an OBD1 meter to check it.
So that's pretty much it. Does anyone have any advice for me on what to do for it.
Not sure if maybe the cat is plugging up but it doesn't stink and I would think I'd get a service engine soon light.

 

fuel pressure check is the best place to start. low fuel pressure will not set code. you can unhook exhaust before the cat to see if that changes anything to see if cat is unhappy.

 

So tested the fuel pressure. It was good. 39 at idle. 42 wot. 43 with the vacuum line to the fuel regulator disconnected. Stayed the same with wot. Back to 39 after putting the vacuum line back on.
tried to get it to throw any codes but can't get it to flash. Tried a reader and the paperclip. Won't even go into diagnostic mode.
Not sure what to look at next

 

94 won't flash, have to use scanner. also 94 has a system that some scanners won't scan. best way to find issue going forward is to get a good diagnostic scanner on it so you can see what's happening with the sensors

 

I also chopped up my cat probably around the 1998 time frame. Took a long beefy screwdriver and hammered all that stuff out of the cat. Never had an emissions issue since...lol. i bought an OBD 1 reader for my 94 also a few years back for the CEL (first time in 27 years). The reader said the clutch anticipate switch. When i went under the dash the switch was out of place. The reader i have is the Actron CP 9690. It reads both OBD 1 and 2 and comes with cables for different manufacturers. Just note this reader requires a 12 volt external power source for OBD 1 that comes with the kit. Where are you checking the fuel pressure from? On the manifold? Does the engine rev fast with the clutch engaged (neutral)/disengaged? Have you looked at the EGR? Just trying to help out.

 

I checked it at manifold. I'm in the process of gutting the cat. It's definitely not the easiest task to do. There's some big chunks I can't get broke up small enough to get thru the pipe. Going to keep working on it. I bet having it on a lift would make it easier.
I started it up to blow some loose stuff out and try to get some chunks to the back. It smelled rich after running it for less them a minute.
I'm going to find a shop that can scan it. Hopefully there's some hidden codes in it. Thanks

 

When you knocked yours apart was there some stuff in it that looked like blown insulation? There's some that came out that is white and fiberous. Not much but it seemed weird. This is the first one I've done

 

I checked it at manifold. I'm in the process of gutting the cat. It's definitely not the easiest task to do. There's some big chunks I can't get broke up small enough to get thru the pipe. Going to keep working on it. I bet having it on a lift would make it easier.
I started it up to blow some loose stuff out and try to get some chunks to the back. It smelled rich after running it for less them a minute.
I'm going to find a shop that can scan it. Hopefully there's some hidden codes in it. Thanks

 

The EGR looks different then what I'm used to. I had it unbolted but not sure what to look for or check it. Can you give me some inside on it?

 

Make sure the EGR is not all carbon'd up, and that valves on the bottom are closed. Use a wire brush, dont use carb cleaner. As far as the cat goes, i dont remember what came out, but do remember alot of chunks like you described. I removed the cat and did it on the bench. Also this gen does not have O2 sensors after the cat so there should be no performance issues with emissions (unless of course it needs to get inspected.)