The exhaust manifold side duct in the head was clear on the one I recently examined, the only clog was where the EGR cooler plate meets the EGR duct in the cylinder head on the EGR valve side and was easily broken up and removed with a thick wire tool. The EGR gas is obtained from the #2 and #3 cylinders. I now have a spare EGR cooler plate and can cut a gasket for it from gasket stock before removing the one on the car. That might not matter if the plate stays open for a long time after cleaning it out. It's putting it back on that I'm worried about the most I guess using RTV would work but that plate won't be coming off again after that without removing the cylinder head. Yeah, I've seen that bolt break off on the second one I removed in the boneyard, but not the first. Thanks ozzie, excellent info, I really appreciate it. Use brake cleaner (you'll need a couple cans) and a very long screwdriver to break up the big stuff, then a baby bottle brush if you want to go really nuts. Then pull the EGR and throttle body off the intake manifold, and pull the manifold off the car. You can also pull the exhaust manifold, that should get you more access to the egr hole in the #4 exhaust port. Having just discovered that part recently (the only other way to get the gasket is to buy a head gasket set), I used black copper RTV, which would be an absolute bitch to try to get back into the back of the head with it still in the car without smearing it. ![]() Victor Reinz makes a gasket that supposedly fits 89+ 22Rs here, and the Toyota P/N does say it changed in '89, BUT! Both the head and that plate are the same P/N '85-'94, the plate is the same '81-'94, and the early gasket is also the same '81-'89, so the gasket should work. Putting it back on will be the hard part. The cover is probably what's clogged up (my race car had about a 1/4" hole through the carbon), but pulling it will also give you access to at least part of the passages through the head. ![]() Be very careful and use lots of PB blaster, the bolt nearest the exhaust side snapped on my head, and when I was doing some searching a minute ago I found a few other people who had the same problem. If you drain the cooling system, you can pull the cover off the back of the head with a 10MM or 12MM wrench - preferably a ratcheting one. Shit.got caught up with other things and never finished this post.that was 3 hours ago Any and all advice (other than removing the head, which isn't an option right now) would be greatly appreciated! I know many of y'all have worked on lots of these engines (A2O has " worked on hundreds") and this is a common problem. If oil companies can drill 20 miles horizontally maybe there's a way to get a flexible tool into the EGR cooler plate through that cast passage and break up the carbon crap in the plate to where the engine can blow it out? It's about 0.5" diameter and about 2.5" long. ![]() I have access to the cylinder head passage behind the EGR valve that goes to the cooler plate. What worries me is that it's going to be essentially impossible to scrape the old gasket off the back of the head, and unless I do that there'll probably be a coolant leak there. Access for putting one back on isn't great but I think I could do it. What are my options for cleaning out the EGR cooler plate? Can it be done while still on the car? I removed a boneyard EGR cooler plate and it was a bitch to reach but I got it. I need to fix the EGR system or risk a likely emissions failure next year (surprisingly the hydrocarbon emissions are quite low even though she burns a crapload of oil). ![]() The NO is really high because the EGR system is not working and combustion temperatures are too high. Kalifornia has emissions testing and last time the engine barely squeaked by on the NO (nitrous oxide) test at 99.4% of the maximum allowed. I have tried cleaning out the passage in the head that goes from the EGR valve to the cooler plate but there is still no exhaust gas flow even with the EGR valve removed. Like on many old 22RE engines the EGR cooler plate on the back of Annie's cylinder head is blocked with carbon gunk.
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