diy...tapping for egr...?

[pleaidestar]

Hey all....I am still doing a swap in my legacy containing a motor and intake manifold from a vehicle that doesn't have an egr valve ...my car does have it so I am thinking about drilling and tapping for the unit.
Just by looking at the bottom of the intake of the non egr motor I'm thinking it can't be done because there is no tube in place to deliver the exhaust to the intake manifolds chamber, I could be wrong but this is more ore less why I started this topic.
I'm on the fence about tapping the head in place on the block, but I'm worried about where the drill shavings are going to end up. I am going to figure out what size to drill and tap tomorrow as I just got my motor out Saturday night. It looks like a 1/4 npt. If I can't get a headsup on this diy I will probably just use my original I/m and plug the hole where the tube goes and just scrap the egr or buy new heads and make them Guinea pigs.

[pleaidestar]

Any ideas, input, opinions, and related experiences would be appreciated.

[ctbrighton]

In CT 1995 and older vehicles more or less get emissions tested via exhaust pipe, so it really depends on your states' emissions laws.

Is there a sensor in or around the intake manifold/head/egr valve that would register flowing exhaust gasses?

[pleaidestar]

No not at all far as I can tell its got one less sensor than my intake...I'm guessing for the vacuum filter on top. But its no sweat for the emissions here.
That tube that my95 intake has isn't there in the other one I'm just going to make a plate to cover it probably, I got a plug at work in my toolbox that will plug the intake. I just want to be able to convert the 98 intake and head for it j.I.c I have to one day.if I should take the head off to drill and tap the head. Time is of the essence for me now, I can't really afford to the headgaskets.

[pleaidestar]

Is this like the hologram in that movie I-robot....I have to ask the right question to get an answer? Or is it that nobody has tried this before?

[Wiscon_Mark]

I've never heard of this operation before, no, and the DIY forums are not the correct area to ask questions. I'm going to move this topic to Engine/Drivetrain.

Generally this is why people recommend you match the ECU/Wiring to the intake manifold so you don't run into problems like this.

[pleaidestar]

Ok mark...thanks...well I'm doing that its just that the head isn't tapped for the egr either and if I can get the info on the manifold I can do that,then the head will follow...I am a newbie my bad.

[tnrknght]

Typically a car with egr is going to have sensors and actions for the ecu reguarding those sensors. Dropping in a motor without egr might cause it to have issues, Im wondering if thats part of my current problem. No egr on the motor I dropped into my 98 wagon. Do you have pics of your motor? What did it come from?

I personally plan on pulling the proper harness and ecu to match the motor into my 98 shell and hope that solves a lot of headaches.

[pleaidestar]

I do not have pics available on this site yet (on my phone)maybe I can PM you some...but the motor is a 2.2 out of an impreza ob wagon w/5sp. Mine is a 95 2.2 auto w/egr...but I'm going to use my intake and harness, going to tap the head if necessary. Just weighing the pros and cons of deleting the egr system, as well as using the gray top injectors with it and my transmission in power mode...see what happens.

[pleaidestar]

The motor is from a 98 impreza ob still phase 1. I believe manufacture date is 5/30/98....

[anothernord]

Google: "drill head for egr subaru" :cool:

http://www.toronto-subaru-club.com/foru ... l-tap.html (http://www.toronto-subaru-club.com/forums/technical-diy-write-ups-faq/142730-diy-jdm-ej25-egr-port-drill-tap.html)

I did this on my old JDM motor. Worked fine! Just be careful to drill straight.

[pleaidestar]

Aha very informative that thread was...I do feel comfortable doing the tapping the head place now....now for the intake manifold, still not sure on being able to modify that to work.

Well I might have made a deal last night to get another 95 legacy sedan just like mine except the color and its a 5 speed. This guys got a Hard-on for my truck and his legacy is in great shape, he wants a straight up trade for it....so lets see what happens. If that works out I can use the 98 intake on that car.

[pleaidestar]

Well ive given up...f*** it im just going to delete it and live with the constant cel. Maybe ill just do a tranny swap to cure it...

[lord flashheart]

Drilling it in the car is a pain. And its even more difficult if its a 99+ auto trans. If its a 5mt just disconnect the steering linkage knuckle and have a buddy eye ball ya to make sure your strait. dont put too much pressure on it cuz you can hit the exhaust valve.
I believe i use a 3/8 bit for the first part and then iirc you need a 24/64 bit with a 13x1.25 tap. But i would double chexk that since its been a few months since ive had to drill one. The hardest part is getting the thread depth correct. Its better to have shallow threads in this case because the egr tube seals on the tip of the tube. So if you go to deep with the 25/64th bit you will run out of fitting and the tube will flop around.

[pleaidestar]

I can tap the head no problem, and the thread pitch is m16x1.5...what I was trying to figure out is if I can retro-fit the intake manifold that came with the motor, I thought I could do it but since that I/m is not made for egr I now think it can't work because there is no feed tube to lead the sample to the throttle chamber. So I just used my I/m from the 95 ej22...maybe later sometime ill get a manifold from that year that was setup for egr..thanks for your input flashheart but its a no win on that, but it was half expected.