This will be my third egr in less than a year and the second in less than 4 months. They keep blowwing out the end cap and the vacum hose out the top keeps drawing exhaust and heating and cracking the hose. The pictures show the missing cap and the exhaust discoloration at the egr modulator port. The intake is clear and so is the steel tube from intak to block. Any ideas? I'm thinking  that the cap s swedge points aren't deep enough to hold it in.

What year? OBDII could be a bad hose routing and or sensor problem?

It's a 95 1.6 16 valve. 2 wheel drive

Plugged cat? Creating a high and hot pressure back thru the egr port. Just something to check!

Kj

But if the cat was clogged wouldn't that hinder the kicks operation? She still runs perfectly with no codes.

I finally just diagnosed my problems with my kick(may have seen my posts)and it turns out it is not getting enough pressure thru the egr port and it is not closing off the modulator so it is opening too early. No code! So to do a temp fix, I plugged the vsv vacuum port exit with a hose and screw. It still has not thrown a code even though I disabled it! My advice is, check everything! I have had cars with slightly plugged cats run good enough to where the power loss was barely noticeable, atleast minor enough to think the car was plugged. Kick-fix.com says the egr modulator needs 2 lbs. To push it closed. 4-5 lbs. May be messing it up? I'm not saying it is the problem but it could happen. Good luck on your fix!
KJ

I had a slightly pluged cat and it did the same thing. And I see from your other post that your getting the check engine light. Your O2 sensor is probably caked now. I would give the cat a little further inspection. JMO

Just checking in to see if you got your problem resolved?

Went to the local u-pull yard and grabbed two off the only Sidekicks there. Been working great ever since.  Thanks for checking back!