I have a big hole in my Intake!!! What to do??? EGR tube on my 4.2 to 4.0 head swap! - JeepForum.com
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Unread 10-30-2008, 02:24 PM   #1
jeepdude1987
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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?

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[COLOR="Red"]1987 Wrangler YJ RED[/COLOR] 4.2 5-speed, NP231, BFG 31x10.5R15 AT/KO on 15x8 gambler wheels.
[COLOR="Yellow"]Caution!!! Under construction!!!!!! Caution!!![/COLOR]
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 02:46 PM..
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Unread 10-30-2008, 02:38 PM   #2
Burnerman
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1989 YJ Wrangler 
 
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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.
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Unread 10-30-2008, 02:47 PM   #3
jeepdude1987
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Edited for clarity and corrections. So I need to plug the EGR valve tube?
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[COLOR="Red"]1987 Wrangler YJ RED[/COLOR] 4.2 5-speed, NP231, BFG 31x10.5R15 AT/KO on 15x8 gambler wheels.
[COLOR="Yellow"]Caution!!! Under construction!!!!!! Caution!!![/COLOR]
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!
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Unread 10-30-2008, 03:08 PM   #4
Burnerman
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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.
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Unread 10-30-2008, 03:52 PM   #5
jeepdude1987
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1987 YJ Wrangler 
 
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Location: Las Cruces, NM
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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?
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[COLOR="Red"]1987 Wrangler YJ RED[/COLOR] 4.2 5-speed, NP231, BFG 31x10.5R15 AT/KO on 15x8 gambler wheels.
[COLOR="Yellow"]Caution!!! Under construction!!!!!! Caution!!![/COLOR]
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!
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Unread 10-30-2008, 03:59 PM   #6
Burnerman
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A block off plate IS a plug. Remove the EGR you'll see what I mean.
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Unread 10-30-2008, 04:17 PM   #7
jeepdude1987
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1987 YJ Wrangler 
 
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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.
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[COLOR="Red"]1987 Wrangler YJ RED[/COLOR] 4.2 5-speed, NP231, BFG 31x10.5R15 AT/KO on 15x8 gambler wheels.
[COLOR="Yellow"]Caution!!! Under construction!!!!!! Caution!!![/COLOR]
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!
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Unread 10-30-2008, 04:57 PM   #8
swa240z
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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!
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