On that EGR valve, you should also check to see if its leaking. With it off, spray some thin solvent (I used carb cleaner) into one of the exhaust passages. It should not leak past into the other side, if it does, exhaust is leaking all the time, too. This was the problem on my '89, I elected to block off the supply on the exhaust manifold and delete the EGR <img src="/forums/images/graemlins/evil.gif" alt="" />. Truck starts and runs much better - better gas mileage also. <img src="/forums/images/graemlins/kewl.gif" alt="" />

'89 Montero, '90 Montero, both 3.0s and 4drs.
'08 Chevy HHR