EGR Help Please

[gone_fishin]

Can anyone give me any advice for getting the EGR pipe nut off the exhaust mani or intake mani side? The exhaust mani nut seems to be at a less ridiculous angle, but it isnt budging, even with some PB blast and some mild tapping.

[gone_fishin]

anyone?

[terbow]

the exhaust mani side i just used a large adjjustable wrench. the intake side i heard is a biatch

[ProtoType5]

The only way I've found to reach the Intake Manifold side is to remove the intake, and throttle body....It's a bitch, but probably takes less time than screwing around and trying to wrestle your way in there....I'm not touching my EGR until I'm swapping my IM....Not worth the hassle until then...

[gone_fishin]

yeah I'm using an adjustable cresant wrench. did yours come off without a fight?

[ProtoType5]

PB blast and some mild tapping.

Did you try some moderate to extreme tapping???? Large adjustable wrench is the way to go....

[gone_fishin]

The only way I've found to reach the Intake Manifold side is to remove the intake, and throttle body....It's a bitch, but probably takes less time than screwing around and trying to wrestle your way in there....I'm not touching my EGR until I'm swapping my IM....Not worth the hassle until then...

yeah that's what I'm doing right now unfortunately lol

[gone_fishin]

Did you try some moderate to extreme tapping???? Large adjustable wrench is the way to go....

I'm really trying not to strip or mushroom the nut, but i'm giving it some loving.

[brokemp3]

try heating up the nut with a mini torch or something like it i bet it comes right off. just use common sense and dont weld it on lol

corey

[bazooka joe]

ya heat should work!

[gone_fishin]

I ended up just taking off the throttle body, but it's still nearly impossible to get a good grip on the IM side. So, I guess I'll try the mini torch. Did I mention that I absolutely hate seized bolts and nuts?

[gone_fishin]

Has anyone been sucessful with this? If so, what did you do to get the EGR pipe fitting loose from the exhaust mani side? I'm getting really frustrated here.

[gone_fishin]

Thanks for everyone's help on this. I finally got it. I ended up using a 27mm non-adjustable wrench. See the link below for the exact wrench size specifications, I posted a comment in there regarding that. Again thanks for everyone's help and suggestions.

http://www.mazdas247.com/forum/showthread.php?p=2884359#post2884359

[Kansei]

I ended up just taking off the throttle body, but it's still nearly impossible to get a good grip on the IM side. So, I guess I'll try the mini torch. Did I mention that I absolutely hate seized bolts and nuts?

Then how the hell do you tolerate having a Protege??? :P it's seized bolt hell all day every day. Hell, I'm working on one as I type this (stuck bolt in callaway manifold.

[orng1]

LOL I've had nothing but loose bolts on mine. I almost fell into my engine bay as I was removing the EGR on the exhaust mani, I figured it 'd be hard so put a lot of force and almost fell into the engine bay.

[gone_fishin]

LOL I've had nothing but loose bolts on mine. I almost fell into my engine bay as I was removing the EGR on the exhaust mani, I figured it 'd be hard so put a lot of force and almost fell into the engine bay.

(rofl2)

And Kansei, how can I tolerate it? Often times I can't.

Would anyone want for me to piece together a how-to writeup for complete IM removal and reinstallation?

[gone_fishin]

Sucess at last!

http://i107.photobucket.com/albums/m294/zach_tucker/DSC01294.jpg

http://i107.photobucket.com/albums/m294/zach_tucker/DSC01295.jpg

http://i107.photobucket.com/albums/m294/zach_tucker/DSC01296.jpg

[Kansei]

yeah isn't our intake manifold fun to get out? I had a TON of fun replacing the bolts that support the underside of the intake manifold, bracing it against the block.

[gone_fishin]

For anyone that's taking their IM out in the future, a HUGELY helpful hint is to loosen the EGR pipe fitting at the intake manifold first with a 27mm non-adjustable wrench (preferably a flare nut, when your IM is ready to be removed) then take the runner half of the IM off the lower plenum so that all your left with is the lower plenum + the EGR pipe in the engine bay. Having only the lower half makes it infinately easier to navigate the IM out of the engine bay with the EGR pipe intact.

[gone_fishin]

yeah isn't our intake manifold fun to get out? I had a TON of fun replacing the bolts that support the underside of the intake manifold, bracing it against the block.

oh it's a little blasty blast in the words of dane cook.

[gone_fishin]

So I got everything finished the other day, and I went to go crank it and it started fine but kept idling high and then stalling. It would kick up the RPMS right before dying out and I just couldn't keep it lit even feathering the throttle. I finally remembered why. I forgot to seal up the giant freaking whole that the VICS butterfly rod went through. (bang)

No wonder...there was a vacuum leak the size of the state of texas on the lower plenum, and the head was literally gasping for air. So, I've been back to it, removing the runner half and am going to thread a bolt in there with JB weld. Hopefully that will fix the problem.

At least it sounded mean as hell when I was throttling trying to keep the engine going.

[Kansei]

I only used the jb weld when I did it, no bolt. I should probably take the IM back off and do it the right way, huh.. dunno if the jb alone will hold up to teh boOst :)

[terbow]

id never trust jb weld alone. mines being threaded witha bolt as well

[Kansei]

I just forget what size bolt.. one of my roommates it taking me to home depot to get a garage heater and some other things today... might as well pick it up.

[iracemine]

i used JB weld alone to plug the hole. i just made it a mushroom shape. oh and i used a crows foot to put on the EGR pipe on the intake side with the throtal body on and it worked perfict.
as fare as high idle. mine idles high and bogs bad until it warms up (chicago gets cold) with no spikes.

[iracemine]

not sure about turbo though might want to use a bolt. sorry.

[Kansei]

yeah, I checked the vtcs removal guide and he mentioned that a 1/8npt would work well.. and I need a 1/8 NPT tap for my EGT anyway.

now if only I could figure out what size/threading the stuts from the turbo to manifold were supposed to be. this manifold I bought had a messed up thread in one hole.

[gone_fishin]

The inner diamter of the hole where the VICS rod goes through is exactly 8mm. I'd recommend getting a 9mm hex head bolt with a collar and threading it in there after coating it in JB weld.

[gone_fishin]

iracemine, I'm thinking that turbo motors might not have the bog problem pre-warm up, but I guess we'll see. I generally let thins warm up before I drive it anyway. I got into the habbit of just beating the crap out of a cold engine from driving my formerly N/A protege (still a no no, but oh well), but now that the swap is done, I've been making a big effort to allow it to warm up before even driving.

[gone_fishin]

It's done! :) After I threaded the bolt in there with JB weld to seal up the giant vacuum leak, it started up like a charm. It idles normally, no bogging. At idle, the exhaust actually burbles now-- I can't believe it. When you give it throttle just in nuetral, it sounds MEAN as hell. It sounds like a track car. Unbelievable, I can't wait to take it for a test drive. (cabpatch) I'm smiling ear to ear.

[Crazee D]

ya heat should work!

BLAH!

Yeah heat will work...I'll have Josh post up a pic what we used to cut off the EGR pipe