I have a big hole in my Intake!!! What to do??? EGR tube on my 4.2 to 4.0 head swap! - JeepForum.com

 
LinkBack Thread Tools
post #1 of 8 Old 10-30-2008, 03:24 PM Thread Starter
jeepdude1987
Registered User
1987 YJ Wrangler 
 
Join Date: Dec 2007
Location: Las Cruces, NM
Posts: 510
I have a big hole in my Intake!!! What to do??? EGR tube on my 4.2 to 4.0 head swap!

I changed the exhaust manifold and now there isn't a hole for the EGR tube so I am eliminating it, and I need to plug the hole in the intake! What should I do? What did you do? Will the EGR valve stay shut with the Nutter bypass?


1987 Wrangler YJ RED 4.2 5-speed, NP231, BFG 31x10.5R15 AT/KO on 15x8 gambler wheels.
Caution!!! Under construction!!!!!! Caution!!!
Finishing a 4.0 Cyl.head swap, Just got an AX-15 NP231J combo to replace the busted t-case and craptacular BA10/5. Adding Nutter bypass. Probably more to come before it is back as a DD!

Last edited by jeepdude1987; 10-30-2008 at 03:46 PM.
jeepdude1987 is offline  
Sponsored Links
Advertisement
 
post #2 of 8 Old 10-30-2008, 03:38 PM
Burnerman
Registered User
 
Burnerman's Avatar
1996 ZJ 
 
Join Date: Oct 2006
Location: Vernon, NJ
Posts: 4,758
What? which manifold has this big hole? The intake manifold will be fine as long as the EGR valve seals and has the vac hose removed and capped.

96 ZJ.
05' Grand Cherokee Limited, 2"OME lift
Burnerman is offline  
post #3 of 8 Old 10-30-2008, 03:47 PM Thread Starter
jeepdude1987
Registered User
1987 YJ Wrangler 
 
Join Date: Dec 2007
Location: Las Cruces, NM
Posts: 510
Edited for clarity and corrections. So I need to plug the EGR valve tube?

1987 Wrangler YJ RED 4.2 5-speed, NP231, BFG 31x10.5R15 AT/KO on 15x8 gambler wheels.
Caution!!! Under construction!!!!!! Caution!!!
Finishing a 4.0 Cyl.head swap, Just got an AX-15 NP231J combo to replace the busted t-case and craptacular BA10/5. Adding Nutter bypass. Probably more to come before it is back as a DD!
jeepdude1987 is offline  
post #4 of 8 Old 10-30-2008, 04:08 PM
Burnerman
Registered User
 
Burnerman's Avatar
1996 ZJ 
 
Join Date: Oct 2006
Location: Vernon, NJ
Posts: 4,758
You can fab up a block off plate for the EGR. I made one out of a sheet of alumiium and put it under the EGR valve. If you take off the EGR you'll see how it works. As long as you don't have a vacuum leak you're OK.

96 ZJ.
05' Grand Cherokee Limited, 2"OME lift
Burnerman is offline  
post #5 of 8 Old 10-30-2008, 04:52 PM Thread Starter
jeepdude1987
Registered User
1987 YJ Wrangler 
 
Join Date: Dec 2007
Location: Las Cruces, NM
Posts: 510
That means I am going to plug it. I would only trust my jeep to keep from having a leak till I was in the middle of F'ing nowhere and wasn't expected back for a week. Thanks. Do you know where I could find a plug?

1987 Wrangler YJ RED 4.2 5-speed, NP231, BFG 31x10.5R15 AT/KO on 15x8 gambler wheels.
Caution!!! Under construction!!!!!! Caution!!!
Finishing a 4.0 Cyl.head swap, Just got an AX-15 NP231J combo to replace the busted t-case and craptacular BA10/5. Adding Nutter bypass. Probably more to come before it is back as a DD!
jeepdude1987 is offline  
post #6 of 8 Old 10-30-2008, 04:59 PM
Burnerman
Registered User
 
Burnerman's Avatar
1996 ZJ 
 
Join Date: Oct 2006
Location: Vernon, NJ
Posts: 4,758
A block off plate IS a plug. Remove the EGR you'll see what I mean.

96 ZJ.
05' Grand Cherokee Limited, 2"OME lift
Burnerman is offline  
post #7 of 8 Old 10-30-2008, 05:17 PM Thread Starter
jeepdude1987
Registered User
1987 YJ Wrangler 
 
Join Date: Dec 2007
Location: Las Cruces, NM
Posts: 510
I don't want any welding and I want to be able to just go to a store and buy it, but no one could tell me where I could find one.

1987 Wrangler YJ RED 4.2 5-speed, NP231, BFG 31x10.5R15 AT/KO on 15x8 gambler wheels.
Caution!!! Under construction!!!!!! Caution!!!
Finishing a 4.0 Cyl.head swap, Just got an AX-15 NP231J combo to replace the busted t-case and craptacular BA10/5. Adding Nutter bypass. Probably more to come before it is back as a DD!
jeepdude1987 is offline  
post #8 of 8 Old 10-30-2008, 05:57 PM
swa240z
Registered User
2000 TJ Wrangler 
 
Join Date: Sep 2006
Location: Southern Indiana
Posts: 219
The threads are some wacked out metric thread and I couldn't find anything to fit BUT I have a fairly simple fix for you.

In order to make sure you have no future vacuum leaks, remove the EGR valve and install a blocking plate using new gaskets. Next, take the hollow bolt/nut that the old egr pipe went through and remove it from the pipe. Run a tap down inside that bolt/nut so that a pipe plug can be threaded down into it. Use some teflon tape on the plug and the nut to make sure everything seals good. Thread the bolt/nut back into the intake and you're all done!

That's what I did and it worked perfectly!

Yellow 2000 TJ, 4.0L, NV3550, 3.73 gears. 4" RC X-series lift, 33x12.50x16 MT MTZ's on 16x10 MT Classic Bead Locks. Bumpers, winch, axles and gears coming soon.



./l ,[_\_\ ],
l---L –OlllllllO-
()_) ()_)--o-)_)
swa240z is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the JeepForum.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid e-mail address for yourself.



Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.




Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page



Similar Threads
Thread Thread Starter Jeep Forums Replies Last Post
intake manifold hole on bottom? Under carb vanwent YJ Wrangler Technical Forum 8 03-18-2013 04:44 AM
Head unit hole filler for yj RedWind Wrangler General Discussion 8 05-23-2009 08:36 PM
4.0 Head Swap Intake Question BostonD YJ Wrangler Technical Forum 10 01-01-2009 02:47 PM
4.0 head swap, 4.2 intake does not fit!!! help johnrezz YJ Wrangler Technical Forum 8 11-15-2008 10:29 AM
HELP! wtaer comming out of hole on top of new head ultra TJ Wrangler Technical Forum 15 06-01-2005 05:21 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome