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A friend pulled his plenum on Friday night to replace his injectors. He is new at the mechanic thing and decided to try it himself. After pulling everything he was a little intimedated and called me. I showed up to pile of vacuum lines, bolts, and rubber water line ripped out of the engine... not to mention 2 broken fuel injector connections. Either way, it seemed I had a bit of work on my hands. After doing the water bypass on his car and replacing his fuel injectors along with fresh injectors I took off for the night and decided to tackle the rest the next day. The next morning, impatience got the better of my friend and he ended up fitting on the plenum wrongly and bent the EGR fittings that insert into the bottom of the plenum. The flanges would not line up with the bolt holes and it took the better part of 4 hours to keep attempting. I had no intentions of rigging the EGR to bypass the flanges but found a way. After calling Spee and a few other folks, I soon deducted that the EGR is activated by vacuum line pressure. So if no pressure went to the system and the EGR tubes were blocked it would make the system inopprable. BASICALLY, I just cut the EGR tubing in the middle of the tube (about the center of the valve cover) with a dremel cut disc. I plugged plenum holes on the bottom of the plenum with a self made metal plate that plugged the hole. I then took JB Weld and inserted it into a syringe I had lying around and shot it about 3 inches deep into the now cut EGR tubing. After 3 fills I then bent the end of the tubes closed and JB Welded over the tips once more. Then I just capped of the EGR vacuum line. I was hesitant at first, but now that we did it.. it all worked very well. It wasn't my first choice but it worked well until we pull the engine one day, and can bypass the EGR the correct way. Just an idea for you guys out there to think about if you ever in a pickle. Anyways, worked out great. Got the car running a few days ago and it ran like a champ.
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