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Hi George,
I just got the two posts in my mailbox now?
The EGR and line to the intake was badly plugged here.
I forget how I got the EGR valve cleared, I soaked it in carb cleaner
and maybe that isn't good enough, I remember picking at it with some
sharp tools. You might try warming it up carefully and trying oven cleaner on it. I didn't try it, but it might work.
I cringed when I heard that you had the intake manifold off and didn't
clear out the EGR port! If oven cleaner can get that crusty stuff to soften up,
maybe you can clear the blockage with a small flexible piece of snake wire
in a drill bit from the outside? It's such a PIA to pull the intake manifold
I'd consider pulling the stuff at the throttle body so I could get a shop vac
in there and then drill and tap a new fitting in the intake manifold, or even easier Just drill one small hole to JB weld /epoxy a small small brass fitting or tubing of the right size. You'd need to prevent chips from the drilling from getting loose in the manifold of course. When I did my 95 850, it was badly plugged at the top and the oil separator was just fine.
Your rehab plans are solid, don't forget to flush the tranny, there's some
videos explaining it, and beware of power flushes at garages.
Post back with your results and comments,
Bill
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