So I finally got to do the intake manifold/egr clean. Pulled the manifold off and the port was clogged solid. No wonder why I was getting a CEL every 3 to 4 days. I bought the egr/fix kit and drilled out the passage: 27/64" drill? Really? Off to the hardware store...
Once done and the tube installed I flushed out the manifold with carb cleaner and then a garden hose to get out the aluminum. Pulled the valve covers off and other than a couple of clearances just out of spec all were in line. Not bad for this many hard miles and a real tribute to Mobil-1. The inside looks brand new with only a clean film of oil- no varnish or anything.
Motor idles super smooth and pulls a lot stronger as well. Back to chirping the 225/55's off the line again!
At this rate I won't be getting that new car anytime soon.

I know shoulda taken pics.

 

you actually paid for the sleeve in the egr port?
Its still going to plug up on you--make a note to redo in 50-75kmiles
99s only have 1 port so it takes a hit on the clogging

 

It was in the box with the new egr. I realize drilling out the port is the real benefit and in theory the smooth finish of stainless tube is better than the relatively porous aluminum cast. But what's the diff? A difference of a few thou before it constricts and clogs?

Also, I am sure I am not the first to realize this but other than the electric connectors and vacuum lines you do not have to remove the coolant hoses or throttle cables when removing the throttle body from the intake.
Makes the intake removal real quick like in the next 50+ thou!

 

Why did you have to replace the egr valve?

the reason to pull the TB with manifold is to access its underside and clean the idle air control `IACV`
if just doing the acura method-(which was least labor for the job since it was a recall) you can leave TB on car
BUT
We should be lubing the throttle cables and throttle return spring assembly, which requires the cables come off the TB and their mount assembly!

 

I removed the egr once before when the codes started to indicated insufficient egr lift.
It had a pretty good ring of carbon around the valve. So with the discount on the parts I figured at 160 it couldn't hurt.
I did clean the TB and air control valve passages.
I just found it easier to remove the TB bolts and sensor connectors and gently push the unit off to the right rather than remove the cables and water hoses and take the whole thing out.
Placed a big towel underneath it and cleaned away.
The cables always get a shot of silicone with my normal maintenance and the gas pedal is real smooth.