View original topic: intake air dist + blocking off EGR port?
airkooledchris Tue Jan 06, 2009 10:32 am

many here have removed their EGR equipment over the years - what did you use to plug the port on the intake air distributor once it was removed to keep away any vacuum leaks?

im only getting around 11HG of vacuum currently and I think this is one of my bad spots, but im not sure what to fab or buy or whatever that will help keep it tight and not fail again at a later date.

busdaddy Tue Jan 06, 2009 10:42 am

Make a new gasket without the middle hole and re install the valve.

airkooledchris Tue Jan 06, 2009 11:28 am

so cut a little piece of rubber out and mount the EGR back to the intake air distributor again?


Wildthings Tue Jan 06, 2009 12:15 pm

When I bought my '78 it had a hole in the EGR filter, plus leaks in the EGR valve and would not idle. I pulled a coin out of my pocket and sandwiched it between the flanges where the valve mounts. Got me home fine.

You could easily make block off plates for the air plenum and the port on the muffler from a small piece of 1/8 inch thick steel from any hardware store. You could just use silicone as a sealant on the plenum, but should have an OEM gasket or something else that can handle the heat on the muffler end.

asafk Tue Jan 06, 2009 12:56 pm

took a piece of aluinium, cut it with scissors, and bolted it in place. works just fine.


WhirledTraveller Tue Jan 06, 2009 2:56 pm

I cut a piece of tin from an old metal dustpan. Put a piece of duct tape on the bottom it so it seals nicely and installed it over the hole on the EGR valve (I left the valve in place). I had to use a few washers on the bolts because the tin was much thinner than the egr pipe it replaced.

Traveling Writer Tue Jan 06, 2009 3:07 pm

Like the others, made my cap with a little leftover sheet metal and some gasket maker. Bolted it on, threw the valve and pipes in the basement "just in case"!

mightyart Tue Jan 06, 2009 4:54 pm

I used a flat thick piece of Jeweler's bronze (copper).
And auto silicone gasket to seal it.

airkooledchris Tue Jan 06, 2009 5:21 pm

mightyart wrote: I used a flat thick piece of Jeweler's bronze (copper).
And auto silicone gasket to seal it.

thanks everyone, and esp mighty for the great pic showing this as well.

ill tackle this in the next few days and see where my vacuum is at afterward...

patayres Sat Jun 13, 2009 11:26 pm

My '75 Westfalia (1800 EFI) is missing all EGR parts below the EGR valve (filter has been lazily cut off below the tin and not plugged). It looks like later EGR systems fed into the plenum from the valve; mine attaches to the throttle valve housing via a long metal tube. I just want to make sure I close up the system properly. Am I safe to just remove the valve and metal pipe and plug the opening on the throttle valve housing? Are there any other openings that need to be checked? Of course the hole in the tin would get sealed. Is it alright to leave the EGR plug from the FI harness unplugged?

busdaddy Sun Jun 14, 2009 7:07 am

You are correct, cap it at the TB (or put a solid gasket under the valve), cover the hole in the tin and cap the hole in the exhaust, tape up the wires and you are done.

germansupplyscott Sun Jun 14, 2009 11:05 am

we just made a new kit for EGR blockoff:

Air_Cooled_Nut Sun Jun 14, 2009 4:57 pm

mightyart wrote: ...

Basicaly what I did as well. Scrap piece of metal, cut a piece of 1/16" cork gasket and bolted it down. The PO has welded up the exhaust piece. The left-over parts are kept in a box in the garage because you should never throw away VW parts, always recycle to another VW :wink:

GermanSupply, I used s/s hardware as well. Nice to see your kit take the same, thoughtful route! =D>

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