Date: Fri, 01 Oct 1999 17:28:45 -0700
From: Eric L Wells (Eric_L_Wells@Notes.FH.Com)
The EGR valve is a pretty straightforward replacement, but you DON'T want to follow the shop manual. The shop manual has you remove the intake and there's absolutely no need to do that - you'll make lots of extra work for yourself. There is also no need to remove the turbo. Instead, you're going to remove the runner pipes from the turbo and go in from the side, above the turbocharger unit.
Parts you'll need for the job:
You'll need to pull the airbox, hoses and air pump, then disconnect the runners from the turbo. It is very difficult to reach the two nuts in the back of the turbo above the cat, so get a long extention with a swivel socket to reach those from underneath (If I remember correctly, everything is 10mm).
Once you pull away the runners and air hoses/vacuum lines the egr is right there. Remove, replace, and put everything back together in reverse order.
The flag rate for this is three hours, but it took my a lot longer because I removed the intake like the shop manual said. After I figured out it was unnecessary, I was pissed!
On a related subject, also see the page on how to do an EGR Valve Test. --Steve