EGR system, which parts are missing?

[furgo]

Yet again thanks to the forum, a few days ago I learnt that part of the EGR system on my bus ('79 federal, 2.0l FI) had been removed, apparently a common mod in those buses.

Here are a couple of pictures of what it looks like:

Capped EGR valve (middle top) and 3 holes where the rod to the EGR filter would go across the left engine tin (bottom left hand side, behind the heater blower duct)

A close-up of the capped EGR valve


As far as I can tell:
• The EGR box in the cabin was removed
• The EGR valve on the picture was capped at the still attached bit of rod
• The holes on the left hand side engine tin were left as they are
• The EGR filter is missing
• And I'm not too certain where the EGR filter would attach to the left heat exchanger or muffler on a '79 bus (so far I've only found pictures of it attaching to a pre-'79 heat exchanger with the triangular flange)

While I'm aware that there is an ongoing debate on whether the engine runs better with or without the EGR system, and I'm not planning to rebuild it anytime soon, I would like to understand what's missing and what it would take to bring the bus to original condition on yet another subsystem.

So the questions I've got are:
• If it can be told from the picture, other than the EGR filter, the rod from the EGR valve to the filter, and associated gaskets, which EGR-associated parts are missing?
• Once the parts are sourced, what would it take to get the EGR system working again? I.e. would it be a matter of assembly, or would there be a calibration to be made?
• Where exactly in the muffler or heat exchanger does the EGR filter connect? I.e. where should I be inspecting for holes to have been covered after EGR removal in the exhaust system?

Thanks!

[JaimeH]

Looks like you have all the moving parts in place. The EGR box under the dash only illuminated a dash lamp at certain milage intervals and was not part of the working system. You are missing the metal connector pipe and the EGR Filter. The connector pipe is the same as used on earlier models. The EGR filter and crossover pipe which it connects to are specific to '79 federal only.

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1978 Transporter 2.0 FI, BA6
Special Thanks to Razor's Customs, Boscawen, NH

[furgo]

Excellent, that's exactly what I was looking for, thanks!

Looks like on my bus the connection of the heat exchangers is directly to the muffler?

That or I cannot make much sense of the muffler and the crossover pipe relate to each other on http://www.oldvolkshome.com/2exh7279.htm#251D.

[busdaddy]

Your crossover pipe has been replaced with a 72-74 muffler, nothing wrong with that, but to use the EGR you'll have to tap in somewhere and do some custom plumbing. The EGR for that style of muffler came off of one of the tubes below where they connect to the head, a 73-74 EGR filter would likely be a better choice for that.
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[furgo]

Ah, that makes sense, thanks a lot for the follow up!

So for future reference in case I ever need to replace the exhaust system, it seems my bus is equipped with:

- 071-251-053E: 72-74 muffler without EGR port
- The heat exchangers connect directly to the muffler. No cross-over pipe, no EGR port

Whereas the stock setup would have been:
- 071-251-053C: muffler
- 039-251-497: crossover pipe
- The heat exchangers connect to the crossover pipe, which in turn attaches to the muffler via a connecting pipe (with optional CAT).

I found a picture of what such stock setup would have looked like (with CAT included) on this thread.

All these with the associated gaskets, connecting pipes, etc.

[JaimeH]

Bus Depot used to sell a muffler with an EGR port.

_________________
1978 Transporter 2.0 FI, BA6
Special Thanks to Razor's Customs, Boscawen, NH

[furgo]

Ah, good to know, thanks! Using one of those should keep things easy, then.