I was bored today, decided to work on the car. I had an EGR block plate b4, but gave it to Coil222 cuz i thought i was gonna sell my car. Decided to keep car, so i had to make another.
This mod will require the OBDII work around if you have an OBDII car.(obviously). Not sure how it will work with OBDI.
Tools:
12mm socket w/ nice extension
Dremel w/ cutting discs and metal grinder
Drill w/ 9/16" bit
Material:
a small section of stock steel
To Start:
Let car cool down for a while before you start to work, the area around the EGR is tight, and you'll most likely burn yourself if you work on a hot car.
Step 1
Remove the wire harness, and the vaume line, and place aside. Then remove the 2 12mm bolts that hold the egr on. The EGR flares out towards the top, so you'll have to come in at an angle to get the bolts out. Sometimes a swivle socket works best.
Bolt 1
Bolt 2(i already removed it for this pic)
Step 2
Take the EGR out of the car. The holes that are in the manifold are what you will be blocking. with the egr out of the car, you'll need to place it on your steel, and drawer some lines around it to get the exact size of the block plate. Make sure you accurately mark your holes for the bolts.
Holes in manifold
Trace around EGR
Cut lines w/ bolt holes(it helps to use the end of the steel so you don't have to cut as much!)
Step 3
I Cut out the two outer edges first. It seemed to be the easiest route to do. Make sure you have plenty of dremel cutting discs. The cutting could take some time depending on how thick your steel is. I put the steel in a heavy vice so that it would not move on me while i was cutting. Remember to protect your eyes while cutting this, sparks and debris are flung all over. After i made the cut w/ the cutting disk, i used the grinder w/ the dremel to smooth over the edges.
Outer Edges cut, and cleaned up
Step 4
I drilled out the holes next. Trying to cut out the holes after the plate was cut would be a pain because of how small the plate would be. I opted to cut the holes while i had a bit of steel to clamp down on. I used a 9/16" drill bit for the holes. Use some motor oil on your drilling points to keep your bit from heating up. After the holes are drilled, line them up w/ the EGR. If they are off, drill them out so they match the EGR.
Holes drilled
Making sure holes line up w/ EGR
Step 5
Cut out your last section of the plate w/ the dremel, and grind down the rough edges. Place in car to make sure it fits over the studs. Make sure there are no bends in the plate, and it is flat as can be. Any bends wouldn't insure a proper seal, and exhaust gases could leak.
EGR Block plate in car
Step 6
Place the EGR on top of the block plate, and tighten down the two 12mm bolts. Re-attach vacume line, and wire harness.
EGR back in car, on top of plate
Make sure your OBDII work around switch is to the off position. This is a 2 start error. First time you start your car, you won't get a CEL. If you start the car again w/ the block plate, you will get a CEL
UNLESS YOU HAVE THE OBDII WORK AROUND Then you are safe to go!
I think that is it.