So, I removed the actual EGR itself no problem, but I can tell I'm going to have a problem removing the tube... The wide, diamond shaped part is no issue, but for you guys that have done it, how did you get the actual part in the exhaust manifold out?

Is there some kind of a special tool that I can get that off with? I can't fit my crescent wrench in there without taking everything else out first... Which I plan to do later, but not for a bit.

Also, when I >DO< remove the other stuff, what size plug should I use to block the second hold in the exhaust manifold?

well your just gonna have to get in there witha pair of vise grips and go to town *** a hammer they have the tendencie to rust in, make sure you save the end of the pipe with the threads that goes into the xhaust mani. its a rare size and thread, cut the pipe and get the end welded shut.
have fun:biggthump

Unfortunately, no matter what I do I can't get this goddamn bolt off.

Vice grips won't fit, and the only thing I have that WILL fit. (cresent wrench) seems to just be stripping the bolt...

Does anyone have any other techniques? Penetrating oil seems to be doing nothing.

I'm talking about the bolt on the very top of the exhaust manifold, on the right (looking at it from the front) side that connects the egr tube from the intake mani to the exhaust mani.

try to use a 15/16 wrench i think that the size i use for that stupid EGR SHHIIITTT..

I just left that pipe on there. I blocked off the diamond shape part of the intake manifold with a plate I cut and I capped the end of the tube that goes to the BPT. So it is still on there but just not doing anything. Much easier than trying to remove it.

Hacksaw pipe off at nut, remove header, weld shut, replace header.

Or in my case, go with an SSAC header and it comes with block-off plugs.

ebay header, why would you be removing emmisions stuff if your car isn't even modified to the point of having a cheap header? i'm talking $130 shipped i mean come on now

Yeah well I just got fired so anything above free is too much... tom. I have some free time and I'm going to take off the oil catch can then get a better angle.

sounds like the easiest way is to cut it off while its still in the mani and stick a cork or somethin in it... how hard can it be?

Unfortunately, no matter what I do I can't get this goddamn bolt off.

Vice grips won't fit, and the only thing I have that WILL fit. (cresent wrench) seems to just be stripping the bolt...

Does anyone have any other techniques? Penetrating oil seems to be doing nothing.

I'm talking about the bolt on the very top of the exhaust manifold, on the right (looking at it from the front) side that connects the egr tube from the intake mani to the exhaust mani.

-Can of PB-Blaster (swear by this as best of the best after pulling apart many rusted pieces). Better than liquid wrench and other liquids. Let it sit, then rap it with a hammer to help break the bonds on the threads - just don't go nuts with the hammer :)
-Low heat (propane torch) - I know, it gets hot all the time, but when the car is cold, heat the area around the bolt on the mani from the outside..
-Cold - there are cans of probably mix of compressed nitrogen and something else, their only purpose is to make something really cold, quick. I saw these at autozone or a box store, I forget.

You should be able to pick up a side exhaust mani plug once you get it out from people like me who bought headers but have no use for the plugs, I have to run the EGR full in CT to have a hope of passing emissions.

HTH

heat and wax