How do you remove the EGR system w/o Screwing up the engine?

[Soravia]

OK, I got the block-off plate in today and tried to remove the EGR top unit from intake manifold. I already have the bottom canister removed. Feed back pipe from exhaust to top EGR unit has been cut. On the front the unit next to the battery has been removed and the vaccume hoses were left loose.My engine is a 91' KA24DE, btw.

The EGR top unit is a 2 piece and I managed to remove only the top piece. the bottom piece (which gets feed back from exhaust) has three bolt and only 2 would come out. The inner bolt is so much inside the intake manifold I couldn't get to it even with twist rachet or small 12mm wrench. Got any idea how it can be removed w/o taking off the intake manifold?

I managed to block all the vaccum hoses by using caps. I block them at the front as well. One larger hose up the front was sucking in air like crazy.As for the pipe back from exhaust which has been cut open, I taped it with masking tape and it holds.

The engine having 'Hiccups' under heavy acceleration seems to have lessened (the hiccups didn't show up before I partially removed the EGR) I'm not really sure yet since I don't want to drive my loud car at night while cops are prowling the streets. I felt a bit 'Hiccup' on shift up to 3rd while at 2K rev. Maybe it was low rpm. (I don't rev past 3K and my shift ups are at 2.5K or 3K) I'll try to drive some more tomorrow and see how it is.

[SOHCSE]

Maybe these will help:

zerothread?id=184357

zerothread?id=87409

zerothread?id=40184

zerothread?id=81689

[Soravia]

Thanks for the links. They were very helpful.

The third bold on flange is stilla a PITA.

Quote »I had my EGR crap removed in like 30 mins with the motor in the car, I don't see what the PITA part is. You just need the right tools. Yes a UV joint is required. But every socket/ratchet set I've ever seen comes with 2 of them.[/quote]What is a UV Joint?

[SOHCSE]

Universal Joint

[Soravia]

I have one and still gets blocked my the intake manifold. I'll try 1/4" drive an see if it improves. All my tools are 3/4" drive.

[wa-chiss]

wow 3/4" drive? Thats way too big.

[Soravia]

Hahaha I think I posted wrong. 1/2" is big so the smaller one I have must be 1/4" or something.

Anyway. I blocked all the vaccume lines I can find and the engine seems to be running ok. I actually made a 90 miles highway trip and there was no smoking, hiccups or overheat.Hell I even managed to pull 30mpg on mostly highway trip. (lower estimate, higher is 33mpg)I was using 93 gas and mostly on the 5th, 65-75mph at 2900-3200 rpm.