[Downtown Turbo]

I just tackled this yesterday and it solved all the issues I was having (EGR pump honking and engaging even after the motor was warmed up while I was driving!). Thanks for the tut!

List of tools you will need

Hardware:

The perfect size of drill bit to start with is 11/64, then switch to a 9/64 bit to finish. Otherwise if you use a larger bit like 3/16 like I did you will have issues getting the remainder of the rivets out as the burrs will dig in as you pull them through the other end with pliers and the head will break off forcing you to use a screwdriver or something to press the busted rivet through.

I reccomend using #8-32x2 machine screws instead of the #6-32 x 1-1/2. The #6 screws have a diameter that is a bit less than the size of the holes left when the rivets are removed and the #8 are a bit snugger. Also try to find machine screws with robertson drive ends as they will be easier to tighten as the flat head will tend to slide out easier)

Also if you go with the 2" long screws then you can use nylon locknuts. With the 1-1/2" screws there is not enough thread to make it to the end of the nut that actually has the nylon inserts. It does look more oem with the 1-1/2" screws though (you could use some threadlocker if you took this route) but I would not want to do this job again if the nuts loosened off as it is a PITA to get the pump out (I left the bracket on). I reversed the screws so the long end of the screws don't stick out towards the hose end.

Tools:

- Ratchet (3/8" drive - don't use a 1/4" - too wimpy)

- Adjustable or fixed (9mm) wrench (for final tightening of the machine screw nuts)

- #5, #6 hex sockets (#5 for the EGR bracket bolts and the #6 for the 3 bolts that are holding the bracket to the intake manifold)

- 10mm socket for the single bolt on top of bracket with the easy-tighten clips that hold one of the pump hoses (bigger one) and rad hose

- 9mm socket for the machine screw nuts to get them most of the way down until you have to switch to the wrench as the socket will not fit between the nuts and the pump housing for final tightening

- Robertson stubby to match to match the machine screws