Question: Finally fixing my long standing EGR trouble codes. After removing the upper intake to clean all hoses / pipes, now reinstalling all.
Cannot seem to get the rear passenger side bolt into the back of the intake. Seems to be misaligned. All other bolts in fine. Anyone have similiar problem?
Significance?
As an FYI to others, the pipe that I believe was causing my problems in the one in the back of the intake, drivers side, that is bolted on with 2 bolts, and goes down to behind the EGR valve with another 2 bolts.
The pipe was packed full of carbon, as well as the packed opening in the intake.
The larger pipe that exits the EGR and goes horizontal to the exhaust manifold, was fairly clean.
Can't wait to see no trouble codes come back!

 

i had that problem when i did my replaced my injectors...it is a pain in a butt to get that one in...but i used my cousins help and got it in there..
let someone hold the manifold and whiggle it while u tryin to put the bolt in.

Good luck

 

how did you get the EGR tube ( that goes up and down) off?
I find the one that goes sideways blocks access to the lower right bolt of the egr tube..

 

 

Appears that you have some nasty rusty corrosion. Mine looked alot cleaner. I removed the large tube first, from the EGR, and then the other end off of the exhaust manifold. Then removed the two nuts off of the part that you show in the pic, and then the upper two nuts on the other end of that vertical tube to the upper intake. This is the key to the carbon build up. That tube was packed solid with hard dense carbon.
Finally got all back together last night. Was able to get the other bolt back into the back of the intake manifold by loosening the lower end of that braket that goes to the block.
Damn upper intake manifold gasket was backordered, so I cleaned up the old one and used Permatex RTV (red) sealant. Put some Marvel mystery oil & fuel inj. cleaner, along with full tank of premium fuel to clean out all of the loose carbon. Ran rough at first, but now runs great & real smooth.
Reset the computer, and so far no engine light.
Next project is the half shafts due to split cv boots.........

 

I didnt reinstall any of the stock brakets, too much of a PITA.

 

This is how i did it.
I hacksawed that part of the bolt like I showed in the picture.Then I removed the iacv. After that I just removed the 4 bolts on the egr tube. I cut that part off so that I could get a wrench on that bolt without removing the large tube.

 

I'm amazed that you were able to get a hacksaw in there and actually use it!
Not much space to work with. The big pipe came off real easy.

 

Took me about 10 minutes to hacksaw the bolt. The hacksaw I used is the one that has the handle part only goes about half the length of the hacksaw itself. So,the other end of the hacksaw is not attached to anything. Very easy to use for this job. I'll upload a pic of it when I have some free time.

EDIT: I used a hacksaw similar to this

http://www.absolutehome.com/assets/i...nley15-809.jpg

 

How did you remove the big pipe? Esp. where it attaches to the exhaust. If you use a crow foot socket, please let me know the size and where you purchased it.