You can just block off the EGR passage and you will be fine.
Go to the auto parts store and buy a rubber expandable plug. I think the size is 5/8" IIRC. (Around $1.50 or so.)
It is a rubber type of plug with a washer on the top and bolt going through it.
You push it in here and tighten it until it is snug.
It kind of looks like this but with a bolt going through it instead of the copper peice on top.
It only comes with one washer on the top side so you will need to get another washer for the bottom side to keep the heat from getting to the rubber.
I have used these on several cars for the last 15 years or so and they work like a champ for blocking the EGR off.
You can usually find them on one of the isles near the bolts.
I have even pulled intakes off 5 years later and the pulg was still fine.
Or you could tap it and buy a brass plug to plug the EGR passage off.
Either way you don't need the coolant running up to the EGR if you block off the port.
Another alternative would be to buy a phenolic intake spacer. They have the EGR port blocked but they cost more money.
Good luck.
Go to the auto parts store and buy a rubber expandable plug. I think the size is 5/8" IIRC. (Around $1.50 or so.)
It is a rubber type of plug with a washer on the top and bolt going through it.
You push it in here and tighten it until it is snug.
It kind of looks like this but with a bolt going through it instead of the copper peice on top.
It only comes with one washer on the top side so you will need to get another washer for the bottom side to keep the heat from getting to the rubber.
I have used these on several cars for the last 15 years or so and they work like a champ for blocking the EGR off.
You can usually find them on one of the isles near the bolts.
I have even pulled intakes off 5 years later and the pulg was still fine.
Or you could tap it and buy a brass plug to plug the EGR passage off.
Either way you don't need the coolant running up to the EGR if you block off the port.
Another alternative would be to buy a phenolic intake spacer. They have the EGR port blocked but they cost more money.
Good luck.
If you had used the explorer heater feed tube, your problems would be over. It has both the source and return lines for the EGR spacer. The ECT sensor will be a little difficult to install, so it is installed before you install the heater feed tube.
If you had PM'd me before you started, I could have stopped by and given you some pointers. I am running an explorer intake with everything hooked up & working, including all the EGR stuff. Winter Springs is 15 minutes from Chuluota.
If you had PM'd me before you started, I could have stopped by and given you some pointers. I am running an explorer intake with everything hooked up & working, including all the EGR stuff. Winter Springs is 15 minutes from Chuluota.
i got mine all installed, and then discovered i too had forgotten to drill/tap the egr coolant return. but i noticed that the egr nipple in the heater core tubes was in the one tube, and the ECT sensor was in the other tube. so, i got a brass tee and ran the egr coolant return back into the tube where the ECT mounts. it looks kind of funny, but its probably the cheapest / easiest solution.
you can kind of see it in this pic. and no, it doesn't hit the hood.
View attachment 441244
you can kind of see it in this pic. and no, it doesn't hit the hood.
View attachment 441244