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Old 07-26-2008, 05:13 PM
pjc pjc is offline
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Join Date: May 2006
Location: Arlington VA
Posts: 278
A few thoughts, having done this myself (with Lightman's post as a reference):

- It's not difficult, but your first-time R+R will take 1-2 hours.
- Loosen or remove the bracket holding the EGR valve; you'll need the clearance to get the manifold off.
- If you pry anything apart with a screwdriver or other tool, remember the IM is aluminum and scratches easily. Stay away from areas that need to remain smooth.
- Depending on your mileage and operating status of your EGR, the inside of the IM may be caked with gunk. Now's a good time to clean it and lube the butterfly valves. There are threads on this board recommending various products: biodiesel, marine solvents, etc. Whatever you use, it's a messy job. If you can afford the time and a few bucks, consider paying a shop to steam clean it for you.
- With the IM off, check the condition of all electrical and vacuum lines/connections and replace as needed.
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