The Best & easiest way to block the egr....

[cecil bass]

I was wondering if I can get some advice on the best and easiest way to block the egr. I have a few different block of plates and no matter what I can't seem to stop the egr from leaking my precious vacuum........ any idea or write-ups available?
Thanks

I been trying to avoid this, but I guess it's time to weld it up ,or upgrade to new intake. I just need to know if I can pass emissions w/o it

 

[earlbrown]

The best and the easiest aren't the same in this instance. The best (in my opinion) is to put brass plugs in the EGR ports (and run an early intake gasket with no EGR holes).

http://www.turbobuicks.com/forums/787768-post18.html

No chance of them badboys leaking... but you really need a mill to make that rectangle hole into a round one.

another option if you're good with a drill motor is to drill two small holes in the EGR plate and tap the intake for two small screws between the holes.



and if you're really lazy, bolt up the ugly EGR valve with great stuff sealing the faces. You'll probably need a sledge to remove it.

Or just pinch the ugly factory EGR bracket and use it to back up the EGR plate.

 

[cecil bass]

Lol, I see a machine shop in my future........

 

[cecil bass]

Btw earl, what size plugs did you use? And we're they hex slotted brass flush plugs or counter sunk plugs?

 

[earlbrown]

The large one is 1/2 NPT and I'm almost certain the small one is 3/8 NPT.

When you get there, you'll notice the small hole measures out larger than the tap drill size. That's no big deal. The trick is to remove the tap and keep test fitting the plug. That way you don't go too deep and make it ugly If you get the intake gasket missing the EGR port, that plug won't matter anymore.

On the top hole, get a nickel and put it over the rectangular hole. It should center up just BARELY touching the 4 corners. When you get it in place, scribe a line around the nickel and that's your bullseye.


I'm guessing if you're good with a dremel, you might be able to get it mostly round, then clean it up with a drill motor. If you try that method, I'd work SLOWLY and cautiously. That's the one that holds back manifold pressure. Just don't Dremel outside the lines!


If you go this route, you'll really like this mod. I'm pretty happy with how well it worked out when I came up with it.

 

[cecil bass]

Your the man twice!!!!

 

[TurboSmart]

seal with epoxy...
but i wonder if filling the port egr holes makes any difference.

 

[cecil bass]

People really do that?

 

[turbofabricator]

I'm not sure it makes ANY REAL difference. I've been doing it for 28 years, but not positive it does ANYTHING. The EGR only works at cruise, and with most aftermarket chips, they disable the EGR. I still cut the tower out of intakes and weld it shut. Probably a waste of time, though.