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I would not think a bad O2 sensor would cause the symptoms you have. If you suspect the EGR valve, pull it off and look at it. It's only a 10 minute job. At least you will know how dirty it is.
With the overheated exhaust system, that you describe I would be concerned about the cat. converter,however I'm not familar with how a faling cat converter would act. Maybe someone thats had one fail could describe the symptoms.
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