I was just searching the other day about how to block up my EGR system and came across a possible solution that wasnt tested (or at least it didnt sound like it was). Put a block off plate in between the head and solenoid; leave the pipe coming from the intake manifold to the solenoid, but then figure out a way to put a filter pre the solenoid. This is what the guy came up with for no CEL. "This = flow test (pass).
"Leaving the EGR connected = EGR function test (pass).

The flow test meaning that filter would draw in air into the intake manifold and then also the solenoid still hooked up. Sorry you guys probably know all this without me having to explain it. So has anyone figured out a way to use a filter to bring cleaner cooler air back into the intake manifold instead of the exhaust. Thanks!

Edit: Sorry I just realized this and I'm probably an idiot. Is the odd shaped thing coming straight off the head the EGR solenoid or valve? I was thinking the solenoid but its probably the valve. If so where is the soleniod?

We used a fine mesh stainless screen to "filter" the intake air at the EGR solenoid on the head. I would imagine that, if you really wanted to, you could just wedge some double 00 steel wool between there and it would serve it's purpose.

Mine is now just flat blocked off and removed. Secondary IAT in the manifold and a plate over the port on the head. CEL is my copilot. If I do anything further to fuck with EGR, I will do the resistor mod like everyone else.

:twitch

Is there any way that you could post a pic of your set up PLEASE!!!
It would really help a lot; I have an idea of what you mean, but am having trouble picturing it. Where does that mesh screen go and it set up the way I sort of explained it in my post?
Edit: "the intake air at the EGR solenoid" I cant really picture it. Sorry. I pic would be awesome!

id imagine that would work for non turbo but what about turbo cars. a filter on an egr valve would be a big boost leak during boost i would think. unless its a one way valve i dunno.

It's only open during light load / no load conditions. Since a turbo depends on load to spool, it won't be a boost leak at all.

On the 4G63 cars, this could be problematic, as the air that would be takes would be unmetered, which would result in running lean, and drivability issues.

I like the idea of running a resistor in place of the solenoid, and running a relayed resistor on the O2 sensor that is being fed to the ECU. When the ECU opens the EGR valve, a resistor is brought inline with the O2 sensor signal, indicating the re-burn of exhaust gasses. Note that our PCM does not check EGR flow with the standard RPM drop, like a lot of other cars - it checks by opening the EGR valve, and watching for a corresponding drop in upstream O2 sensor voltage.

I'm not sure, in other words, that having the EGR valve pull in fresh air would prevent an EGR fail / insufficent flow CEL.

clipse2g95, if your car is a 95 as your username implies, you shouldn't get a CEL at all if you remove the whole pipe and valve. Just leave the solenoid (UFO looking black disc thing) hooked up to the vacuum source and you'll be OK! I have my EGR removed in this manner, as do most 95s, with no CEL. Block that bitch up!

Thank you very much for that VERY useful info!!! That'll save so much time in figuring out a way to filter the air out. So you really dont get a CEL from that? I wonder what the difference is with 95's. thanks again man!

Not a problem at all, Its "common" knowledge regarding the 95 model year. Its one of the few benefits that 95s have, being OBD1, but OBD2 compliant. Hit me up on email for any questions about this, I'll hook you up. Thanks.