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airkooledchris
Samba Member
Joined: January 25, 2005
Posts: 2711
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 Posted: Tue Jan 06, 2009 10:32 am Post subject: intake air dist + blocking off EGR port? |
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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. |
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busdaddy
Samba Member
Joined: February 12, 2004
Posts: 51149
Location: Surrey B.C. Canada, but thinking of Ukraine
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| Posted: Tue Jan 06, 2009 10:42 am Post subject: |
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Make a new gasket without the middle hole and re install the valve.
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Слава Україні! |
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airkooledchris
Samba Member
Joined: January 25, 2005
Posts: 2711
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| Posted: Tue Jan 06, 2009 11:28 am Post subject: |
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so cut a little piece of rubber out and mount the EGR back to the intake air distributor again?
n? |
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Wildthings
Samba Member
Joined: March 13, 2005
Posts: 50351
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| Posted: Tue Jan 06, 2009 12:15 pm Post subject: |
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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. |
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asafk
Samba Member
Joined: April 15, 2008
Posts: 81
Location: Israel
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| Posted: Tue Jan 06, 2009 12:56 pm Post subject: |
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took a piece of aluinium, cut it with scissors, and bolted it in place. works just fine.
Asaf. |
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WhirledTraveller
Samba Member
Joined: January 09, 2008
Posts: 1399
Location: Cambridge, MA
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| Posted: Tue Jan 06, 2009 2:56 pm Post subject: |
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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.
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1977 Westy, Automatic. Big Valve heads, CS Cam. |
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Traveling Writer
Samba Scribe
Joined: May 07, 2006
Posts: 1112
Location: Florence, Italy
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| Posted: Tue Jan 06, 2009 3:07 pm Post subject: |
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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"!
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Cheers,
Davi
1977 2.0 FI Westy
2011 1200cc Yamaha Super Tenere
1976 Feet (they work surprisingly well) |
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mightyart
Samba Member
Joined: March 24, 2004
Posts: 6188
Location: Portland, Oregon
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| Posted: Tue Jan 06, 2009 4:54 pm Post subject: |
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I used a flat thick piece of Jeweler's bronze (copper).
And auto silicone gasket to seal it.
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airkooledchris
Samba Member
Joined: January 25, 2005
Posts: 2711
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| Posted: Tue Jan 06, 2009 5:21 pm Post subject: |
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| mightyart wrote: |
I used a flat thick piece of Jeweler's bronze (copper).
And auto silicone gasket to seal it.
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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... |
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patayres
Samba Member
Joined: March 20, 2009
Posts: 991
Location: Bend, Orygun
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| Posted: Sat Jun 13, 2009 11:26 pm Post subject: |
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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?
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1975 Westfalia Helsinki - 1800 EFI w/ Pertronix
1965 Singlecab - 1600dp
yuthi'so'coro |
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busdaddy
Samba Member
Joined: February 12, 2004
Posts: 51149
Location: Surrey B.C. Canada, but thinking of Ukraine
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| Posted: Sun Jun 14, 2009 7:07 am Post subject: |
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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.
_________________
Rust NEVER sleeps and stock never goes out of style.
Please don't PM technical questions, ask your problem in public so everyone can play along. If you think it's too stupid post it here
Stop dead photo links! Post your photos to The Samba Gallery!
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germansupplyscott
Samba Member
Joined: May 22, 2004
Posts: 7093
Location: toronto
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Air_Cooled_Nut
Samba Member
Joined: March 27, 2004
Posts: 3040
Location: Portland, Oregon
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| Posted: Sun Jun 14, 2009 4:57 pm Post subject: |
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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 
GermanSupply, I used s/s hardware as well. Nice to see your kit take the same, thoughtful route! 
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Did I mention that I'm an original Darksider?
'72 VW Squareback, 2007cc, GB 5-speed, rag top; '76 VW Riviera Penthouse Sundowner 2.0L; 2015 Audi S5 Cabby w/Stage II APR; '06 Ducati Sport Classic 1000; '14 Ducati Diavel Strada
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