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EGR Removal and Coil Wire routing 700 1990

posted by  Steve Hogan on  Thu Jan 31 12:20 CST 2008
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last visit: Mon Sep 29 08:09 CST 2008
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Still getting my "new" California 1990 740-GL wagon with B230F engine with EGR ready for smog. I have already replaced the air filter, cleaned the MAF, cleaned the throttle body and the IAC valve. I am still trying to make my way to the oil accumulator, which I still cannot get to.

I need to remove/check/clean the EGR valve, which is in front of the oil accumulator.
I have removed the sheet metal screw holding a wire bundle.
I have removed both tubing nuts on the EGR.
I have removed the two screws holding the EGR hard outlet tube to the intake manifold. I have not been able to free the EGR from its tubes yet. I believe there is a bolt holding the EGR bracket to the block, but it's buried in the greasy muck. I don't want to break anything, but I need to get the EGR out.
Any Suggestions?

I got an intake manifold gasket in case I need to remove it to get to the oil accumulator, but if I can get the EGR out, I may be able to access it without taking out the intake manifold. I do not have replacemet o-rings for the spark plugs right now, so I'm hoping I don't have to remove the injectors and the fuel rail to get the manifold out.

The coil wire routing was not original on my car. The original wires were replaced with a set of Bosch wires. My car has the L2.4 Bosch system with EGR.
It uses a round Bosch coil mounted to the right side strut tower adjacent to the A/C dryer. The coil wire I removed was routed straight down and then made a u-turn back up to the rear of the engine where it plugged into the bottom of the distributor cap. My NGK plug wires came with a short and long coil cable. There is no way the short one will make it and the long one is the same length as the Bosch wire I am replacing. The problem is that the Bosch wire was leaning/rubbing against the aluminum A/C line feeding the dryer and the wire had the tell-tail white marking where the wire rubbed that happen when a spark plug arcs to a metal body piece. There is an empty wire/hose clip on a small tube attached to the firewall that looks like it might be there to hold the coil wire in space without letting it touch metal. Can anyone supply me with the proper factory routing of that coil wire so that it won't touch metal?

Thanks everyone how has graciously offered help.





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