EGR pipe woes

[afterburners]

Just had my blanked off egr pipe snap off while up at Jone's lake. Limped back home but what a slug since the turbo was affected due to less exhaust pressure going to it. Was wondering if anyone else had looked into blanking it where it mounts to the exhaust manifold as the pipe is quite a "lever" and takes a fair amount of vibration due to it's length which I believe fatigued it and led to it breaking. Any suggestions?

[legionnair]

Most people buy or like me use 1/4" plate steel use the old gasket as a pattern and make block off plates. Make sure you use high heat silicone on the surfaces and anti seize on the bolts. And just remove the EGR totally and put a small machine screw in the vacuum line with a ziptie.

Dustin

[FalcoColumbarius]

Originally, I found a ball of what looked like glazing putty inside the EGR valve, itself. I removed it, polished the inside of the valve super clean. Everything went bad. so I blanked it of with a mild steel plate, worked great ~ until I experienced a galvanic reaction causing the threads on the female end to give up. I literally pulled the bolts out with the Female's threads still wrapped around them. So I had a quarter inch piece of aluminium seal welded to the intake end and an eight of an inch thick piece of carbon steel machined to fit over the exhaust end of the EGR assembly. With this lozenge shaped plate you need a gasket that will withstand extreme heat, so I made one out of brass shim to go between the eighth inch steel plate and the exhaust manifold. This solved any leak issues that I had. There are kits being made for this predicament. Dennis Lambert comes to mind, he has created bolt on 1/4" aluminium blacking plates for the Intake and steel 1/8" plates for the exhaust manifold. There are also write-ups for this in Accessories, Modifications & Ideas", in "L300 Dedicated Category Reference Forum".

Falco.

[sub-arctic]

I dont know if it was a bad thing or not but the gaskets came off my egr and pipe assembly no problem, and not wanting to waste a tube of RTV on a tiny little piece i just re used the gaskets. havent had any problems so far. the i did have a bit of low temp on hand that i ended up using on the little screw i put in the vac line.

[afterburners]

First of all, thanks to Mardy! Who knew that the blanking plate that I had installed on the top of the egr pipe 2 years ago; when I removed the egr; also fits the exhaust manifold port when the rest of the pipe was removed. Now it is blanked again with no chance of another pipe breaking in the future.

[FalcoColumbarius]

First of all, thanks to Mardy! Who knew that the blanking plate that I had installed on the top of the egr pipe 2 years ago; when I removed the egr; also fits the exhaust manifold port when the rest of the pipe was removed. Now it is blanked again with no chance of another pipe breaking in the future.

Are you talking about the lozenge shaped steel plate that fits onto the exhaust manifold? If so, did you install a metal gasket with it so it doesn't leak?

Falco.

[yojimbo]

I didnt bother with gaskets, silicon on the intake side, exhaust sealant on the exhaust side.

[afterburners]

As yojimbo mentioned, high temp. Ultra Copper silicone gasket maker in place of conventional gasket. Just glad Mardy got involved. Simply replacing broken exhaust egr pipe and re-blanking that would in my estimation just be waiting to fatigue again from engine vibration and repeating the cycle. Blanking at the exhaust manifold should be long term solution.

[LeeHammy]

Just a tid bit of visual info as to why removing a EGR is a good thing and having an oil catch can for your PCV. Oil from the PCV coats everything including your intercooler. This then allows all the nasty from the EGR blow off to stick to the oil coating everything in horrible giunky crud. This picture is of what my very clean and well operating 4M40 intake looks like. Let me remind you.... INTAKE.