NISTECH wrote:your egr may not be working cause you have a high flow exhuast that has little back pressure hence the Back Pressure Transducer(BPT) wont close its internal vent to send the vaccum to the egr valve under load.
With the factory EGR pick-up point in the exhaust manifold I don't think the exhaust would affect the EGR operation because there is still alot of pressure built up before the catalyst due to the runner design.
Just my .02
I'd vote funky catalytic converter... mainly because NOx production usually indicates excessively lean conditions or advanced timing due to the increased latent heat of combustion allowing the nitrogen to bond to elemental oxygen. However since you seem to be running rich due to the production of HC's it contradicts the NOx production.
Does the 5-gas report show abnormally high amounts of CO2? If this were the case then you can definately rule out a rich situation as the higher combustion temps and resulting lack of elemental oxygen tends to facilitate the production of CO.
Correct me if I am incorrect.