ENG: EGR removable plugs :)

[wed3k]

This is a great DIY and everyone should do it if you can. I was able to use a drill press so it made things alot easier...but here's my results:





Thanks wed3k!

so did you have to level the manifold or just chucked it up and went at it?

[mndude07]

I wish I could have leveled it perfectly, but I just used a wadded up rag on the drill press table to semi-level it....so yeah, I eye-balled it lol.

[benji]

Anyway to get a refresh on the pictures, Wes?

[wed3k]

those are really old photos so ill check if i still have them on my comp. my photo host probably ate them.

[Bad_dude]

Hey all, so in this DIY i will be discussing and demonstrating how to drill, tap and be able to use pipe plugs in replacement of the oem style plugs/caps.

i have both a H series and f22a6 (thx Juan) intake manifold however i only got around to the A6 and will have to experiment with the H series one and shall update.

(Umm, people usually put that disclamier BS but i dont because who in their right mind would sue me especially when im not giving you advice but rather you are searching for helpful information and using it at one's own risk. assholes)

Tools required:
-Hammer
-flat tipped Punch
-3 drill bits, largest one being 7/16's or 29/64's (so a small, med, large)
-drill
-lube and cleaning fluids
-1/2"-20 tap
-6 1/2"-20 pipe plugs




1. Knock the plugs out of the hole. what i found easiest instead of drilling them out and using a slide hammer was just knocking them all the way into the hole with hammer and punch. i will tell you the reason later.

2. Begin enlarging the hole with the 7/16" or 29/64" drill bit and make sure it is straight. do not touch the second hole!!!! Now that the hole is enlarged, deburr any edges and the plug should just fall out.

3. clean out the shavings produced.

4. use tap and make the thread within the hole. Again, make sure you are going straight in. Every 1/2 to 1 revolution reverse the tap and proceed. feel free to clean the hole while you are tapping. You will hit a certain point and at that moment STOP! dont try and force the tap any furthur or it may break. i marked the tap to give me a guage on how far to go in on the rest of the ports.



5. i also use a file to clean up the edges of the hole. install pipe plug and repeat for the other 5.




Notes:

*The H23 IM has a different design so i will have to experiement and locate where the holes are.

*Something that i have been thinking about, the pipe plug is made of a different material that the manifold so the rate of expanision under heat can differ. the only thing i could suggest using is thread lock and some teflon tape to prevent any leakage. A Phenolic spacer might not be a bad idea considering the spacers prevent a lot of heat being transferred from the engine to the IM. Plus, you need to replace th gasket anyways.

*it took me around 1.5 hours to do all 6 plugs. still debating on the side plug removal for easier cleaning of the ports.

H23


A6

Do you have any pics of the drilling the plugs out portion without using the sliding hammer? So you just keep redrilling the holes with larger bit until the plugs are almost no more and they will fall out?

Thanks.

[ikayto]

if you're in a bind and just want to pass smog quickly...I just drilled through the plug, stopping to clear the shavings along the way. Then I just patched the hole with jb weld after I was finished. Passed smog with 200 NOX PPM, for 15mph. I failed before the clean up at 1500 ppm NOX lol.

No way is my way the way you SHOULD do it, but if you need it done quickly without removing the manifold..it'll work. My engine hasnt destroyed itself from any shavings..yet eeek.

[Bad_dude]

Isn't the side plug is of larger diameter than those 6 on the top? Or is it the same size?

Thanks.

[wed3k]

it's different.

[CB7xTURBO]

damn i need to do this.. but my h23 intake manifold has that stuff on the egr ports that look like weld.. so im going to grind it down..

[10thAnnivCB7]

i want to do this but those pictures dont work anymore ,, is there another DIY like this with pictures ?

[bobbycos]

i want to do this but those pictures dont work anymore ,, is there another DIY like this with pictures ?

very old DIY

could use a pic refresh

[wed3k]

yea i lost the pictures from my old photo host. i have a manifold that i might take apart and take more pics.

[10thAnnivCB7]

that would be awesome man ,, hope you can get them up

[reklipz]

Some photos. Don't do what I did in the last photo!

[Stoner51]

Thanks for posting pics. We need to do this to more threads.
I assume by the last pic you are talking about it being crooked?

Still looks good. I will be doing this this weekend.

steve