Engine/Transmission (1994 - 1998) EGR blockoff plate

[mgause]

Does anyone have a template, drawing, or specs for a plate to block off the EGR orfice on the Exhaust manifold? Not that I would ever consider doing such a thing . I was planning on pulling the EGR tube and drawing up the specs for a plate to be machined from stainless by a shop; however, I don't want to recreate the wheel if any other CA truck owners have already drawn up plans for the same.



-Thanks

 

[Dkevdog]

I took my EGR off my 96 (unless you are a spy for the government and then I KNOW NOTHING ). I eventually ended up putting an ATS pulse manifold on, but until then, here's how to do it.



If you unbolt the EGR tube from the Manifold housing, you can simply use the Gasket as a template. I made one from 1/2" plate steel. Used a simple angle grinder and sawzall to shape it. I might still have it laying around in the garage, if I do I'll PM you later. Nothing fancy, but it worked well.



The intake was replaced with a Banks Non EGR twin ram.



Kev

 

[PHaller]

Call Mag Hytec 818-786-8325 and ask for Jerry. They have them already made up.

-Paul R. Haller-

 

[Reb.B]

just cut out a piece of thin metal or tin or copper and put it between the egr tube and the ex manifold, make sure to pull the gasket out. On the intake side need to put a gasket between the valve and the air intake horn. Boost will leak out of the egr mainfolds. The best way is the throw a 49 state manifold on there, they are almost twice the size and create less turbulance. Also ATS 3 piece is the best to throw on the exhaust. U will eventually need one cause the stock ones shink over time.

 

[mgause]

Thanks for the input. I'm planning on putting on a 49 state air horn so I am going to do away with the EGR tube. Re the exhaust manifold I will replace with the ATS unit when the time comes. The ex manifold on my 1st gen truck cracked at bout 125000 mi. I figure this one will soon with 151k on the truck. Pretty much only upgrade when things break. Of course I have the habit of making things break prematurely.

 

[jburnes]

I blocked off mine and it didn't do anything. I took off the intake and upon further observation a noticed the restriction on the cal trucks is unbelieveable. The problem is, the reduction to create the venturi effect to draw exaust over also restricts the opening which chokes it down to an 1" or so in diameter. The 49 state manifold is full size all the way through. Banks on the otherhand offers a twin ram system which is supposed to distribute air across the 6 cyl more evenly. Well, I have a Banks set-up on mine minus the twinram. It is not a good investment costing $600+- bucks. The force of the boost at 20-30 psi is not going to notice the twin effect as much as Banks claims in 49 state set-ups. In Cal truck it will make quite a difference because it legally replaces the choked down Cal system. I bought a 49 state manifold from Oregon (creative shipping, to friend in Oregon to me) and Well... there you go $85 vs $600 go figure? The intake psi's will be freed up by decreasing drag and opening intake. These measurements are approximate but with the Cal intake your looking at 3. 7 sq/in intake vs a 9. 4 sq/in on the 49 state intake. That's a 250% increase in air flow. Good luck in all your adventures



Sincerely,

JB

 

[mgause]

I sourced a 49-state intake from Cummins West here in West Sacramento for $70 and it should arrive today. I agree the small orifice in the Cal intake horn is a real restriction; however, I see how the venturi effect would be necessary to draw in adequate exhaust gass under low backpressure (i. e. , upon decel or coast). I've been running upwards of 34-35 psi (tapped at the intake manifold) through the Cal horn and I'm afraid I been making the turbo work a lot harder than it should considering the backpressure that must build up upstream of the restriction. Anyway we'll see what happens when its all together.