rossignol292 wrote:
So I've been dealing with this problem for awhile now. The EGR pipe extends from the exhaust manifold, around the back of the engine, and into the EGR valve. The pipe has a flange on the end that sits right on the EGR valve, and is bolted to the EGR valve by a piece of steel. In my situation, the flange cracked and broke away from the rest of the EGR pipe. I have the Eco tune, so my EGR is shut off. However, this problem allows exhaust to leak into my engine bay (which is loud and costs me some boost pressure).
I've tried a number of products to seal up the leak, but none have seemed to work. Thermo steel and other exhaust repair putties/epoxies fall off within days. The best I've found so far is copper RTV with has lasted as long as 2 months. I'm convinced it's because RTV is flexible enough to deal with the vibration (lots of vibration down there). But even the high heat RTV ultimately failed because it's not meant for these applications (sealing a gap as opposed to creating a gasket). So now I'd like to try other sealing products that are designed to seal gaps and remain flexible. My only question is, how hot do you think this area gets? It's right on the engine block, and the EGR valve even has coolant running through it. However, the EGR pipe is connected to the exhaust manifold (albeit a short distance away). Once it's sealed, there shouldn't be much exhaust gas circulating through it because, as i mentioned, i have the eco tune cutting off the EGR.
In short, I need to figure out the temperature of this area to I can find a sealant that is flexible, and able to handle the heat.
Thanks everyone.
I had this problem..
The best way it fix it is to remove the EGR for good. (this is what i did)
1. Remove the pipe from the exhaust (clamp) and EGR valve (two bolts)
2. Take the pipe to a welder, have him cut the pipe to 1 inch
long at the exhaust side and weld it shut.
3. Install the 1 inch long pipe with the original clamp.
You could be done at this point if you place a cover on the EGR with the two bolts. But i would continue.
4. Completly remove the EGR, cooler and intake elbow with the butterfly valve.
5. Install a heater hose from the line that went to the EGR, now directly to the Head.
6. Remove the butterfly valve from the elbow and remove the flange from the valve. (the flange is where the intake hose clamps to)
7. With 4 new smaller bolts and sealant bolt the flange directly to the elbow. (eliminating the valve)
8. On the lower side of elbow you will need to reinstall the clamp with a small blocking plate. (I made a small disk from sheet alum. You may want to file down the elbow a little for fitting)
9. Install the elbow to the intake and hookup the intake hose. (there is room for the hose to pull up a bit and fit without the valve)
There you go... no EGR system!
Any questions ask or PM me.