so after countless work that ive done on the egr system it just wont stay unclogged.  my intake is so carboned up its not even funny.  so i was about to take down to the suzuki dealler and through down 500 cash min to have them work on it.  untill one of them said it would be cheaper just to buy a new lower intake manifold.   so from them its 420 with gaskets. but have anyone had theirs hot tanked?  how much was it.  or where might i find a cheaper manifold.
holla atcha boy.

What manifold do you need. I have one from a 16v 1996 if you want one cheap and then you can have it hot tanked yourself.

PM me. There would be shipping involved but not a big deal.

Nathan

try this first.Remove this tube (in red) pull it out and down as shown by the arrows. be careful not to loose the gaskets. They are reusable. Use carb cleaner to clean out the tube. I then used a pic, coathanger and a Qtip to clean out this elbow (yellow). I sprayed a ton of carb cleaner up in there too. It will start pretty hard when you put it all togather but it wont hurt anything.

mikr

My 16V doesn't have that tube.  I guess there were at least 2 variants of emission systems on these bad boys.

I wonder if there is somethging not quite right with the setup. Neither of mine have a modulator so I'm not familiar with that setup. Is there a reason why its clogging up so often? Could it be that the valve isn't opening/closing at the right time - engine too cold maybe? Is it burning oil or running rich?

My 16V doesn't have that tube.  I guess there were at least 2 variants of emission systems on these bad boys.

yea, mine also doesn't have that tube ... on mine the gas passes through the lower half of the intake runners.

From what I understand, if the engine is burning some oil (rings or valve guides or ...), then the oil residue in the exhaust gases will condense onto the cooler walls of the tube/passage (especially when the engine is shutoff)

Having it put in the hot tank at the local automotive machine shop will get alot of the carbon out and make the rest easier to remove. On the other hand if carb cleaner and elbow grease will clean it. Your choice once again comes down to Money or time. Its a factor in every decision we make isn't it.

ya mine doesnt have the tube.  but it doesnt look fun to do.  money's not an issue.   just sold some pups got 4g's to give to this money pit.  vortech lighting swap sounds better and better.  but ya to the guy with the intake woulda 96 fit this. mines a 94.

I think it was in 96, when they went to the external EGR tube.
I just got through cleaning a complete intake and EGR system on a 96.  It was on a 4 door sidekick I picked up, and started working on to get it road worthy.  It had a "low EGR flow" code, so I pulled the intake tube and opened up the butterfly valve, to have a look at the port in the intake manifold that goes to the external EGR tube (which is usually where the restriction is located).  What I found was about 1/4" of soft, oily, black crap stuck to the backside of the butterfly valve and after removing the complete intake manifold, I found it was all caked up on the inside with the black, oily stuff.  Between hot power washing and about a case of brake cleaner, I finally got the complete intake manifold and EGR system clean.
I haven't gotten it back together yet, to see if the code will come back, once I clear it.

man, these systems are re-god-damn-dicklious.lol   does anyone know how much hot tankin it is?  probly cheaper than 400 right?