KA24DE EGR Emission Removal Diagram Pics Write up will follow

[Soravia]

This is the way to correctly remove the EGR emission control system from the KA24DE engines. This is complete removal which will have you fail emission test in most cases but still run the engine well enough and not have many issues concerning enviromentally harmful stuff.

The entire intake manifold will need to be taken out and it's gaskets replaced. You will also need replacement tubes for the PCV from the engine to the intake manifold as they are very old. One other thing you will need is something to block the exhaust feed back pipe unit. Many people resort to JB weld but I recommend SEARCHING ebay for 240sx EGR Block plate.Go to Auto parts stores and get some vaccume hose plugs. You need at least one.

If you want to clean the intake manifold, you MUST have Seafoam Engine cleaner, metal bottle brush with twisted wire handle, a small but long flat head screw drive for hard to reach places and 2 bottles of brake cleaner to clean up afterwards.

You will need Hi-temp cold-weld to block the hole on back of the upper intake manifold after you remove the butterflies and the unit controlling it. The screws on the unit are very hard to remove due to the washers being tight. I had to use a cutting wheel on them. The screws themselves came out easily once the washers were gone.

The diagram

[Soravia]

This is the EGR Block-off plate found on eBay. It's mild-steel and a direct fit on the intake manifold. Taking out the EGR unit and it's pipe shaves off around 4 lbs.After the EGR unit was removed.

[Dcrprez]

Awesome, but I can't see the diagram!!