sorry to ask this again but i need more info on egr aiv removal. ok i took off silver aiv in front of the engine that connects to manifold i also took off the big black thing on the right next to this that connects to the intake.do i need to re install this and cap off the plastic piece where the aiv hose hooked up to or cap off at intake and leave off?this also has a rubber hose that goes to the valve cover do i cap this hose off or do i need the 2 black boxes on for this.now onto the two disks on intake manifold, i took off the disc on the driver side and i see where to make a plate for the egr on the side of the intake and i plugged all the vaccum lines do i need to remove the disk towards the passenger side it is bolted to the intake manifold and do i need to make a plate for that to or do i leave that one on and just cap off the top where the hose was. pics would be very helpful. thanks!

i have a 91 ser forgot to add

Let me see what I can give you in the way of info. The PAIR system right next to the radiator is ok to remove. Just plug the hole going into the manifold and the one going to the air box if you have the factory airbox still. Don't remove the black box behind it. It is an oil separator and there is no reason to remove it. Plugging those holes can cause crank case venting problems. When removing the EGR system on the intake... all you have to do is get some sealant and make a cover plate that covers the 2 holes left after you remove the EGR diaphragm. I used a piece of aluminum and cut it to the right length, used the gasket to line up the holes and drilled the bolt holes. Then I used the factory gasket which I covered with sealant. Bolted the plate on and DONE with that!!! I had a shop cut the pipe from the manifold right at the bolt and welded a plate over the bolt so I could plug the manifold. I hope this helps bloke.

Cossie

would the ECU need to be reprogramed for non-AIV and non-EGR operation?? i removed my EGR system and one day my engine was baking hot!!! so i replaced it and it runs fine now...

so what do you do with the metal tube that runs from the exhaust manifold to the intake manifold that has the electrical connection and vacumm on it? do you just cut the metal tube off where it ends and fill it then bolt it back on to the intake manifold so you can make the electrical connection?