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Old 03-18-2011, 12:25 PM   #4 (permalink)
Clev
Wannabe greenie
 
Join Date: Aug 2008
Location: Yorba Linda, CA
Posts: 1,098

The Clunker (retired) - '90 Honda Accord EX sedan
Team Honda
90 day: 29.49 mpg (US)

Mountain Goat - '96 Ford Ranger XLT 4x4 SuperCab
90 day: 18 mpg (US)

Zippy - '10 Kymco Agility 125
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Sorry, I thought that the page had the same instructions as the PDF I saved a couple of years ago. Here's the procedure I found for the 90-93 Accord "without removable EGR passage plugs":

Quote:
For easier access to the EGR ports remove the IAC Valve and Fast Idle Thermovalve from the front of the intake manifold. You should be able to see a machined boss on the top of each intake runner about 2 inches from the head. The four bosses are all in a line and are parallel to the head.

Center punch and drill a 5MM (or #8,#9) hole in the center of the boss. This is the proper tap drill size for 6MMx1 which is the size you will tap this hole later in the repair process. Remember to put grease on the drill bit to catch the aluminum chips and drill just far enough to get into the EGR runner.

You can now clean out the EGR port by running a rod (or drill bit) through the port and into the intake manifold. You can also use decarbonizing chemicals and compressed air as needed to help clean out these ports. Tap the holes 6MMx1 (remember to use grease in the tap's flutes to catch the aluminum chips). Install 4 - 6MMx1 short flange bolts, with sealant on the threads and flange.
Are you the original owner? If not, maybe the previous owner had a shop do this work, and they welded the holes closed instead of tapping and bolting them?
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