Bigsyke
11-02-2008, 05:18 PM
I was a little confused, everybody said I had to remove the IM. I just finished removing the whole EGR system in 2 hours, spent less than $5 and didnt remove the IM - and I have huge hands. No pix yet.
-100k ohm 1/4 watt resistor
-10" if 14ga wire
-2 nickles
-your version of an EGR block off plate/plug
10mm socket
12mm socket
A small saw to cut EGR pipe
1st, remove the exhaust mani heat sheild. I then cut the exhaust manifold EGR pipe as close to the m24x1.5 bolt as possible. I bent the pipe down so I could get a wrench in there. Broke the bolt loose, put 2 nickles in the port and torqued it down - no leaks. If you can then cut the pipe a little further upstream so it can manuver out easier.
Then I moved to the IM side. Removed all brackets holding the Brake booster hose. Removed fuel pressure reg hose and brake booster hose. remove all vac lines going to both egr valves. Unbolt the egrc-bpt and manuver it out. Next attack the EGR valve with a 12mm socket. There are only 2 bolts, if your unbolting 3 then you need a custom 3 point block off from ebay. Once you have unbolted the EGR valve you may need to rotate and wiggle the whole assembly out. There is a large plate thats bolted with 2 10mm bolts to the firewall, you may need to remove that POS and toss it if you ahvent. If you have A/C then you maybe in for some trouble. I think a line runs back there.
The EGR valve will come out, trust me. Once its out, inspect all the hoses. There will be the Evap/EGR solenoid down behind the block, right below the 4th runner. I unbolted the 10mm nut, unclipped the harness plug and pulled off the vac lines. Removed the solenoid. There are now 3 ports connecting to the back of the block, use some vac caps to seal those.
Inspect the hoses, mine were cracked. If you have a EGR block off plate install it, I used a rubber plug that was cut to size and plugged the hole.
Then down below runners 2 & 3 there is the EGR temp sensor. I made a custom harness/resistor assmbly. I took 2 14ga wires, soldered each end to the resistor, heatshrinked the whole thing then wrapped it in loom. Then crimped red crimping couplers on both ends. I made a U. Looks stealth and clean. I snipped the wires at the sensor, took the wires and pulled them up through runners 2&3. I then used the 100kohm 1/4watt resistor setup and crimped it all together. Self explanitory.
Made sure all hoses were secure, cleaned up and I officially removed the EGR system in 2 hours.
-100k ohm 1/4 watt resistor
-10" if 14ga wire
-2 nickles
-your version of an EGR block off plate/plug
10mm socket
12mm socket
A small saw to cut EGR pipe
1st, remove the exhaust mani heat sheild. I then cut the exhaust manifold EGR pipe as close to the m24x1.5 bolt as possible. I bent the pipe down so I could get a wrench in there. Broke the bolt loose, put 2 nickles in the port and torqued it down - no leaks. If you can then cut the pipe a little further upstream so it can manuver out easier.
Then I moved to the IM side. Removed all brackets holding the Brake booster hose. Removed fuel pressure reg hose and brake booster hose. remove all vac lines going to both egr valves. Unbolt the egrc-bpt and manuver it out. Next attack the EGR valve with a 12mm socket. There are only 2 bolts, if your unbolting 3 then you need a custom 3 point block off from ebay. Once you have unbolted the EGR valve you may need to rotate and wiggle the whole assembly out. There is a large plate thats bolted with 2 10mm bolts to the firewall, you may need to remove that POS and toss it if you ahvent. If you have A/C then you maybe in for some trouble. I think a line runs back there.
The EGR valve will come out, trust me. Once its out, inspect all the hoses. There will be the Evap/EGR solenoid down behind the block, right below the 4th runner. I unbolted the 10mm nut, unclipped the harness plug and pulled off the vac lines. Removed the solenoid. There are now 3 ports connecting to the back of the block, use some vac caps to seal those.
Inspect the hoses, mine were cracked. If you have a EGR block off plate install it, I used a rubber plug that was cut to size and plugged the hole.
Then down below runners 2 & 3 there is the EGR temp sensor. I made a custom harness/resistor assmbly. I took 2 14ga wires, soldered each end to the resistor, heatshrinked the whole thing then wrapped it in loom. Then crimped red crimping couplers on both ends. I made a U. Looks stealth and clean. I snipped the wires at the sensor, took the wires and pulled them up through runners 2&3. I then used the 100kohm 1/4watt resistor setup and crimped it all together. Self explanitory.
Made sure all hoses were secure, cleaned up and I officially removed the EGR system in 2 hours.