How to: EGR Delete, tube block off.

[Alex_M]

Just a small quick post for those who want to block off their EGR, for those installing headers or whatever else reason. I will give a brief explanation and then just drop a few pictures in. If you wish to block it off at the exhaust manifold as well (not pictured), take a new EGR gasket to use as a template. Trace onto some 18ga or thicker steel to place between the exhaust manifold and the EGR tube. You can remove the tube and just put the flange back over the plate if you are completely removing the system.

For the intake manifold block off which is what I have pictured, start by removing the tube from the intake. Using an angle grinder with a cut off wheel, cut off the neck that sticks into the intake manifold as pictured. You can see that I cut a bit more material than I needed to, hopefully you will leave the body intact. Take two 3/8 washers, a 3/8 bolt, and a 3/8 nyloc nut (IMPORTANT - MUST USE LOCK NUT TO PREVENT BOLT FROM LOOSENING AND FALLING INTO YOUR ENGINE). Cover space between washers with RTV, as well as the bolt hole so that the assembly is completely sealed. I put the bolt head inside the intake with the nut on the outside, both so that there is minimal intrusion into the intake stream as well as so that in the unlikely case that the lock nut were to start loosening, I would be more likely so see it. That's it, now simply reinstall this assembly into your intake manifold and the EGR is now deleted. If you remove the EGR valve is disconnected and remove, you will have to have a tuner make it so that EGR codes are not reported. Otherwise you will have a perpetual check engine light.

 

[Alex_M]

 

[Donal]

I have considered installing a plug with a half inch orrfice in the end that extends in the the intake. Goal is to reduce the recirculation exhause gasses with out triggering the CEL light. Plan on reducing or increaseing the orrfice to satisfy ecm. Also have to gather data on before installtaion, to compare to after installation. Not sure what gains in performance or mpg to expect.

 

[Alex_M]

If you leave the EGR valve in place and connected to the wiring harness then there should not be any code thrown at all. The ECM only checks to make sure the valve is there and using the correct amount of power, not that exhaust gases are actually circulating.

That said, you should not see any gains in performance or mpg. For performance, exhaust gases don't circulate under high load. For mileage, if there is any effect it would actually be an increase in mileage to have your EGR functioning properly.

The only benefit here is increasing simplicity and decreasing engine bay clutter. Modern EGR is actually a pretty good system.

Edit: I will try to also take some screenshots and add to this post to show how to disable EGR in your tune file if you have HPTuners.

 

[kbit]

I just used a freeze plug, forgot the diameter exactly but you can measure it. Its a good fit, I just smeared a bit of rtv on it. Looks good and doesn't intrude into the throat at all.