Yes I took the egr valve off and shot brake clean in there, then used a bunch of pipe cleaners to clean it out really well. I then seafoamed the piss outta the engine. It did run noticeably better after but mileage was not affected. I am not average BTW, as I do my own axle regears, rebuild my own engines, etc. I turn my own wrenches and more. Thats why this is so frustrating, as it is some oddball rare problem that has got me stumped.
I have so far run a compression check - 180 lbs all cyl, fuel pressure check - spot on, new injectors, cleaned egr - new egr gasket, no vacuum leaks - constant 18-20 in HG, new intake air temp, new map, cleaned TB and new gasket, new plugs, wires are pretty new - checked resistance - less than 1k ohm, new upstream oxygen sensor, new cat, checked exhaust for restrictions - none. Checked ignition timing and replaced rotor - spot on 12 degrees at 700 rpm hot.
Like I said the only thing on the scan tool thats a little wack is my downstream oxygen sensor is pretty slow to heat up and read anything. Ill prob just replace it as it is 90k old. As others have said there header is not causing an issue I dont see how that could be the cause.
Does anyone have their old factory manifold and cross over pipe for a 2.3 vtec?