anyone ever remove/clean the EGR on their XL7?  any tips/tricks?  it's in a bad spot, I think I have to remove the intake manifold to get to it.

150 views and no inputs?  weather permitting I'll be taking the IM apart next weekend to see what's the best way to access the EGR valve

almost done solving this -- I took the rear air passage off the intake manifold which has the EGR valve and throttle body attached to it (as well as the EGR pipe leading up from the exhaust manifold).  what a PITA.  found a LOT of oily gunk built up in between the valve & IM to the point where one of the ports was nearly completely closed off!  cleaned it all out with a small knife and a lot of carb cleaner and cleaned out the intake manifold pretty well too. 

here's a pic of the intake manifold section I took off and the EGR valve on the bottom side of it.

if anyone else ever needs to do this themselves here's all the stuff you need to unbolt/undo:

-plastic "V6" cover (4 screws);
-rear IM air passage where it attaches to the center section of the IM (2 nuts & 1 bolt on each end);
-brackets for thick wiring harness that runs behind the IM (5 or 6 bolts);
-intake plenum from the front of the TB (1 screw clamp and 2 bolts);
-2 coolant hoses from the sides of the TB and 1 air hose underneath it;
-throttle and cruise-control cables;
-hose leading from back of the IM to the PCV valve;
-various electrical connectors from the TB and top of the IM, as well as the one from the side of the EGR valve;
-EGR pipe that goes from the passenger side exhaust manifold up to the rear of the IM. (has 2 bolts on either end as well as a hidden one on a bracket in the middle just above the tranny.)

finally here's a pic of the (cleaned) valve and the little spring-loaded piston inside it which you can grab with some needle-nose pliers and verify that it moves back and forth freely.

also, on the electrical connector you should verify that the resistance on each of these pairs is between 20-24 ohms:  A-B, C-B, D-E, F-E.  if any are out of spec you should replace the valve.

Great write up!!  How does it run now?
I too am getting a CEL for the EGR.
S

Why does these things plug up.?