Ok, it is installed. Man, what a pain in the ASS!!!
Here is the exact way I did the install. I followed a guy named 94TBlazer @ S-Series.org.
Thread is at http://forums.s-series.org/viewtopic.php?t=23334
Here is what he said.
The EGR valve is located on the front of the intake manifold just below and to the passenger side of the "throttle body". There are two 10MM bolts holding it on and both are a PITA to get to, but not impossible.
Remove the short pencil brace from the back of the AC compressor to the manifold. This makes room to remove the EGR valve. There's one 13 MM bolt and a 14 MM nut.
Next remove the air cleaner box and intake hose from the throttle body. I take it out as a unit. The IAT sensor is on the bottom side of the hose to the throttle body, don't forget to disconnect that.
Disconnect the electrical connection from the EGR valve. Now you are ready to remove the EGR bolts.
From the front of the engine, the RH bolt is the toughest. Get a 10MM socket and a long extension. Go straight at it, just under the electrical connection on the valve. Be careful retrieving the bolt, as there's no room for your fingers and it can easily drop. I have a telescoping magent that I use to make sure I don't drop it.
The bolt on the other side just requires a 10MM box-end wrench and many 1/16 turns.
Once the valve is unbolted, work it out where you removed the pencil brace.
Looking at the valve removed, the are two ports. A large one and a small one with a pintle that has a torx-socket depression in the center of it. Look for any small carbon chunks keeping the pintle valve from seating. If there is, you've found your problem and need to pick it out.
Regardless, take a can of carb cleaner and spray liberally in both holes to remove as much of the deposits as possible. If the valve is seated, you can push it down to make sure the carb cleaner gets into the port and seat.
Once that's done, go back to the truck and inspect the ports on the manifold. If there's any chuncks there, do the same and pick them out. Then spray again with carb cleaner.
Ok, here is where I start in again......
With the EGR removed, I screwed the studs into the existing holes. The left one went in fine but the right one was an absolute bitch to get in enough to bite the threads and get a good hold. The threads were a little rusty on that side so I installed everything once but didn't get enough bite so I had to take everything out again and start over. Man, stressful.
I then took the old bolt and screwed it in and out numerous times to get the rust out and put a little bit of oil to lube it up a bit. I retried putting in the stud and gladly, I was able to get enough of it in there to bit properly. I slid on the one EGR gasket, the restrictor, another gasket and the valve. To everyone, the valve will take some work getting into place and took at least 10 minutes itself to get in properly.
Ok, well, I put on the nut on the right stud an tightened it slightly then worked on the bitch of a task of getting the left one on. It will take some work and the paper towel in the socket trick will help you.
Ok, it's installed, WHEW!
While the intake was still off I took the liberty of giving the throttle plate a good blast and whipe with the throttle body cleaner. It was pretty damn dirty and I got all the grim out so it would seat properly on idle. With it in clean shape, onto the intake.
I reinstalled everything and found that my K&N Filtercharger was a little dirty so I rotated it 180 for now so the clean part was available for the incoming air coming into the filter intake box port.
Now I also noted that the filter lid was not hooked on properly and has been open on the bottom end for the past year. I reset it up properly while it was out of the truck and it's back to normal.
Also, everyone, make sure your pipe clamps on your intake hoses are tight. The clamp attaching the assembly to the engine was finger tight which might be causing some problems. It was finger tight and really easy to loosen off so when I reattached it, I made sure that it was nice and tight.
THE TEST DRIVE
Welp, I was really nervous when I reattached the negative battery cable and hooked up all the sensor and it was go time for the startup. I hit the key and the engine fired up within two rolls of the engine. Now, this isn't normal, but the throttle body cleaner probably in the intake allowed for the quick startup. The engine spit and sputtered a bit until it cleared the cleaner and the idle smoothed out pretty well, but there was a miss here and there. So, I shut it down and waited 5 minutes while I had a gulp of coffee and a relaxing smoke (I was so stressed).
I fired it up again and let it warm up and idle down and the first difference was noted.
Idle dropped 50-100rpm. Nice and smooth. It hasn't idled this nice in a while.
Ok, now the true test, on the highway.
Getting my space to pop onto the street through traffic, I gave the throttle a little bit of a push and it is true.
RESPONSIVENESS IS UP
Acceleration was noticable stronger also. And no guys, I am not imagining it. Acceleration was indeed smoother, stronger and a lot more constant. All is well and I'm impressed.
I tripped over to the local Petro-Canada gas station and threw in 40 liters of 87 octane fuel and gave the tank a shot of fuel injector cleaner. Then it was off to a Tim Hortons drive through for a coffee for the highway test drive.
After the drive through, I went up a sidestreet which had a moderate incline and the engine did power up the hill with a little more ease, another problem showed its head.
Pinging was definitely happening more often. But only within the 1900-2300rpm range. IF I stomped on the gas, the pinging would instantly go away and the truck would accelerate, and boy, does it accelerate now. WOW!
Also, If I'm idling along at 80kms per hour and 1500-1700 rpms there is nothing, the engine purrs perfectly. Only on moderate acceleration and going up hill while accelerating does it happen.
Now I also noticed that the engine is now less willing to downshift while going up hills and it likes to power up then which is a definite improvement. Before, if there was any incline while at highway speeds, the engine would kick down a gear quite easily. Good to see that it is fixed or at least better now.
The pinging and lifter clatter is really bad at about 2100rpm and at highway speeds.
Now, I'm wondering if I got a shit tank of gas or I need to go up an octane level to counteract the less exhaust going into the engine. The burn will be a little hotter, so maybe a cooler burning, higher octane fuel is in order.
Another thing I am thinking about is that the air filter is plugged. It's definitely dirty and maybe the engine is now a little staved of air seeing that it night have the need for more because the exhaust in the cylinder is less.
Now on the otherhand, remember that I said that the air filter box wasn't set up properly and was sucking in air directly onto the filter from the bottom. MAybe now that i have sealed it back up properly it isn't getting anough air. Would make sense. Air staved engines will tend to ping and rattle a bit.
Now, also, the engine computer was reset so maybe it needs some time and driving to get things properly configured and setup correctly. I only drove it about 15 miles for the test, so maybe I need some more time.
So many things to test, so little time.
Anyone have any ideas or seen the same thing with there restrictor?