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EGR Block off plate leaking


MadMax_636

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Ive been having this issue with my EGR block off with it leaking exhaust into the intake and causing it to run really bad and most of the time stall/die.

How have yall done your block off plates? Ive only started having this issue recently. When I first did the duraspark mod/upgrade I never had an issue.

Ive got a thick starter shim that luckily fit perfectly and under it between the EGR port and the plate. Ive got a fel-pro EGR gasket. It keeps leaking sometime. idk what to do...
 


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cbxer55

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The EGR block off plate on my Lightning is on the plenum above the supercharger. I used black RTV when I installed it. Never had an issue. But, I don't have any of the EGR stuff either. It's all gone. The block off plate just attaches where the EGR tube used to attach.
 

MadMax_636

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The EGR block off plate on my Lightning is on the plenum above the supercharger. I used black RTV when I installed it. Never had an issue. But, I don't have any of the EGR stuff either. It's all gone. The block off plate just attaches where the EGR tube used to attach.
Do you have any photos? Where did you get the plate or what are you using as a plate?
 

ericbphoto

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This is for 90's model 3.0l's, but yours would be remarkably similar.

It should look about like this.
20210501_210949.jpg



And bolt on here, in place of the EGR valve.

20210501_211001.jpg


Since there won't be any exhaust gas flow, heat is not an issue. A simple gasket or good quality liquid gasket material should work. A chunk of steel or aluminum 1/4" or thicker with a really flat sealing surface should work great. 30 minute project with a hack saw, drill and file.

Or check your local junk yard. Once you have dimensions, I think you will find a lot of vehicles have identical plates there, not just Rangers or Bronco II's.
 

MadMax_636

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This is for 90's model 3.0l's, but yours would be remarkably similar.

It should look about like this.
View attachment 59386


And bolt on here, in place of the EGR valve.

View attachment 59387

Since there won't be any exhaust gas flow, heat is not an issue. A simple gasket or good quality liquid gasket material should work. A chunk of steel or aluminum 1/4" or thicker with a really flat sealing surface should work great. 30 minute project with a hack saw, drill and file.

Yeah, Mine looks nothing like that. Heat is apart of the problem... Its got exhaust and intake holes on the same mount... Great design...
 

ericbphoto

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Yeah, Mine looks nothing like that. Heat is apart of the problem... Its got exhaust and intake holes on the same mount... Great design...
I Thought you were wanting a blocking plate for deleting EGR. Are you really talking about the EGR valve?
 

MadMax_636

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This is what I have... Im wanting to block the EGR. Since I dont have ANY of the original ignition stuff. Its the duraspark system.
 

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ericbphoto

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Use what you have there as a pattern to make a new one out of thicker metal. That piece leaks because it is too thin and flexible.

Or send it to me. I'll make one for you. $10 + shipping from Wellford, SC.
 
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cbxer55

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Do you have any photos? Where did you get the plate or what are you using as a plate?
Mine looks very similar to the one pictured in the next post. Yours looks way to thin, that's why it leaks. Needs to be thickerer. I don't think any EGR valves, where that part mounts to the intake, are any different. The one on my 98 Ranger looks like it would fit my 04 Lightning and 07 Mustang.
 

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A chunk of steel or aluminum 1/4" or thicker with a really flat sealing surface should work great. 30 minute project with a hack saw, drill and file.
That's exactly what I did on mine. The starter shim is too thin, and I'm surprised that it worked as long as it did for you. Scrounge up a piece of flat steel, and then hack saw, drill, and file on it until it looks like this:

59392


Paint is optional, but painting my plate did make the truck run faster. :)
 

MadMax_636

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That's exactly what I did on mine. The starter shim is too thin, and I'm surprised that it worked as long as it did for you. Scrounge up a piece of flat steel, and then hack saw, drill, and file on it until it looks like this:

View attachment 59392

Paint is optional, but painting my plate did make the truck run faster. :)
I did cut and drill up a plate. I put a brand new EGR gasket and it started leaking.. So I got some high temp RTV gasket maker around it and hopefully itll make it seal. Im waiting an hour until I tighten it 100% down.

I figured it was idle mix screws were out of sync so I capped off the PVC valve and the engine died. So thats was when I learned it was leaking. Then I broke out the RTV. Laid a small bead around the 2 ports and between them. I also put 2 layers of it. One layer under and another over the gasket. So the gasket has some on the making surface of the intake and one on the outside where the block plate smashes onto it.
 

kimcrwbr1

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I agree make one out of 1/4”plate steel and surface it with 120 grit paper using a figure 8 motion. Then just use a new high temp egr gasket.
 

ford4wd08

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You need a thicker plate like mentioned. I took my gasket to work and had a buddy in the shop make me a plate.
 

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