You need only plug the manifold, or replace it, plug the intake manifold at the vacuum line port.

There is an EGR blocking plate for the intaeik manifold, or was a kit Volvo offered. You remove the intake bits, reuse the old now brittle gasket, or cut new, or use sealant up to the task.

Volvo also offers a machine screw and copper washer to plug the hole at the manifold.

Then remove the EGR piping from where it was attached to the EGR valve and the pipe that connects to the intake manifold that terminate in a flange you replace with an EGR blocking plate or make from steel cans to fit. I used a high temp RTV.

You then replace the EGR enabled Bosch EZK116 ignition control module and the Bosch LH-Jetronic 2.4 injection control module with non-EGR models.

Better to use the newest non-turbo version of EZK116 and LH-Jetronic injection control module.

This page is incomplete and only lists injection ECUs and AMM/MAF models.
No information about the few different Bosch PN's for ignition control module (No or yes EGR).

http://www.nuceng.ca/bill/volvo/database/ecu.htm

Non EGR and Not Turbo. Use 0-280-000-951.

'Cept I still have the EGR EZK116 Bosch ignition control module and no dash error light yet the fault code for EGR.

Have you been inside your air filter box? See the flappy air valve that control inlet or preheated air? Do you have the silver accordion hose connected? Either replace the air dilter flappy valve thermostat with Wahler 70411 or disconnect that silver hose, remove the flap valve, and emission rise a bit with lower fuel conomy in cold months.

I'll guess you are not in NY or CA states where working emission controls are proven by a glance. Same thing in Canada and Germany. EGR is BS.

Questions?

Hope that helps. Back to wurk.
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