Inner diameter of intake elbow?

weeks101 · **Joined:** Mon Jul 30, 2012 3:29 pm **Posts:** 747

Does anyone know the inner diameter of the intake manifold inlet where it connects to the intake elbow, as pictured below?

I am thinking it's either 2" or 2.5"...

Thanks!

weeks101 · **Joined:** Mon Jul 30, 2012 3:29 pm **Posts:** 747

Never mind, I found out.

It's 2.25"

kjjet · **Posted:** Tue Jan 14, 2014 9:31 pm

If your looking for a gasket? I don't like the thin one the MFG uses. I just use some heat resistant sealant and and install the elbow wet. No leaking anymore.

weeks101 · **Joined:** Mon Jul 30, 2012 3:29 pm **Posts:** 747

Thanks, I am actually replacing the entire intake elbow/flow control valve assembly with custom aluminum piping, all the way from the turbocharger to the intake manifold. I'll be using the OEM gasket coated with Permatext Copper RTV. I am also replacing the 4x factory M6 bolts with M6 studs, which will allow me to torque it down more as well as prevent stripping out the intake manifold.

I'll make a new thread with a write-up when it's all finished.

kjjet · **Posted:** Tue Jan 14, 2014 10:07 pm

Nice.. I have no FCV. Boy it makes it clean looking and easy to work around.

Good luck
KJJET

weeks101 · **Joined:** Mon Jul 30, 2012 3:29 pm **Posts:** 747

I bet. Will make glow plug changes a lot easier.

kjjet · **Posted:** Tue Jan 14, 2014 11:02 pm

Exactly. I just had a 7V steel fail. I installed one of my old ceramic ones until I install the new one that arrived today. It takes about a 1/2 hour to do as is. Would take at least 4 hours with all the EGR system installed.

Spending a little time now saves lots later.

FYI... How are your rockers? Rollers should have no movement.

weeks101 · **Joined:** Mon Jul 30, 2012 3:29 pm **Posts:** 747

No idea. I haven't had the cover off.

tomasnc · **Posted:** Wed Jan 15, 2014 8:44 am

weeks101,

I look forward to your thread. Your objective to it totally remove the EGR crap from this engine?

kjjet · **Posted:** Wed Jan 15, 2014 9:22 am

tomasnc wrote:

weeks101,

I look forward to your thread. Your objective to it totally remove the EGR crap from this engine?

Yes, several of us have done this. Mine has been gone for 20k. But sounds like weeks101 is installing solid piping to replace the left and right turbo hoses. I like the idea. If you rev your engine you will see the hoses expand, solid hose will not expand. It should give you better performance.

kjjet · **Posted:** Wed Jan 15, 2014 9:24 am

weeks101 wrote:

No idea. I haven't had the cover off.

Ok? The picture show's a removed intake? Not yours?

weeks101 · **Joined:** Mon Jul 30, 2012 3:29 pm **Posts:** 747

kjjet wrote:

weeks101 wrote:

No idea. I haven't had the cover off.

Ok? The picture show's a removed intake? Not yours?

Correct, not mine.

tomasnc wrote:

weeks101,

I look forward to your thread. Your objective to it totally remove the EGR crap from this engine?

For now, I will be disabling the EGR system using block-off plates, but I will be leaving the system fully in-tact. My next project (after I get a GDE tune, which reverses the function of the EGR so it is actually serves a beneficial purpose) will be to plumb-in a convoluted steel tube with 37° JIC fittings from my new intake elbow back to the EGR valve. At that point the block-off plates will come off and the system will act as a turbo surge "blow-off" valve.

My design will increase flow, eliminate multiple points where a boost leak can occur (there are three gaskets from FCV flange to intake manifold), and make access to the glow plugs far easier.

The return tube to the EGR will look roughly like this but shorter and with different fittings (quick Google image search):

mass-hole · **Posted:** Thu Jan 16, 2014 10:29 am

Looking forward to seeing how this comes out. Will you be using single pieces of bent tube from the Turbo->CAC and CAC->Intake Manifold? Are you making your own flange at the intake manifold side to bolt up to the existing holes?

weeks101 · **Joined:** Mon Jul 30, 2012 3:29 pm **Posts:** 747

mass-hole wrote:

Looking forward to seeing how this comes out. Will you be using single pieces of bent tube from the Turbo->CAC and CAC->Intake Manifold? Are you making your own flange at the intake manifold side to bolt up to the existing holes?

Mandrel-bent aluminum tube with bead-rolled ends. 2" from turbo to intercooler and 2.5" from intercooler to intake manifold.

Yes, fabricating the 4-bolt flange. Will be 3/8" aluminum.

Diver1430 · **Posted:** Thu Jan 16, 2014 1:33 pm

am I correct in that you are bypassing the samco hoses and the intercooler by coming over the top of the engine?
I just removed the EGR and coolier and will be putting the head back on with studs this weekend, I hope. I bought the SAMCO hoses and was going to put it back with the elbow and valve open.
tks
barry

mass-hole · **Posted:** Thu Jan 16, 2014 2:05 pm

weeks101 wrote:

mass-hole wrote:

Looking forward to seeing how this comes out. Will you be using single pieces of bent tube from the Turbo->CAC and CAC->Intake Manifold? Are you making your own flange at the intake manifold side to bolt up to the existing holes?

Mandrel-bent aluminum tube with bead-rolled ends. 2" from turbo to intercooler and 2.5" from intercooler to intake manifold.

Yes, fabricating the 4-bolt flange. Will be 3/8" aluminum.

Very cool. I had tried to get a shop to do this for me but they could only weld preformed ell's and straight pipe instead of doing a custom bent single piece, so I passed.

weeks101 · **Joined:** Mon Jul 30, 2012 3:29 pm **Posts:** 747

Diver1430 wrote:

am I correct in that you are bypassing the samco hoses and the intercooler by coming over the top of the engine?

No. It will follow the factory/samco route. Definitely not bypassing the intercooler.

mass-hole wrote:

Very cool. I had tried to get a shop to do this for me but they could only weld preformed ell's and straight pipe instead of doing a custom bent single piece, so I passed.

I guess I misread your post. Since I don't have access to a mandrel bender, there will be some welding involved. In other words, it's not going to be a single piece bent into form.

The intake elbow piece will not have any welds in it except where it attaches to the 4-bolt flange at the intake manifold. It will bolt into position and be able to accommodate factory CAC hoses, Samco hoses, and my custom made pipes. I already have some interest for the intake elbow from other CRD owners, so I may do a run of them if I can get 5-10 people interested.

I'll post photos when it's all done.

kjjet · **Posted:** Thu Jan 16, 2014 3:20 pm

Weeks101... A few people have done this. The only thing i can add is to caution you not to make the pipes too long. You will need to add a few inches of flex couplings to allow for the movement of the engine. I have seen people pop off the ends or crack the intercooler during a quick acceleration. A new intercooler is not cheep.

Good luck
KJJET

papaindigo · **Posted:** Thu Jan 16, 2014 5:00 pm

The one that I recall used 4 pieces of Samco hose, short lengths from Boost Controller IIRC. 1 at each end of the hard pipe to serve as flex joints.

weeks101 · **Joined:** Mon Jul 30, 2012 3:29 pm **Posts:** 747

I'll be using silicone hump hose connectors designed to flex, with plenty of clearance so as not to damage the plastic end tanks.

Inner diameter of intake elbow?

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