Egr mounting
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Senior User
Joined: Feb 2009
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Egr mounting
Quick question guy's, about 6 months ago I pulled and cleaned my egr valve...when tightening the bolts after re-installing it, i stripped the threads on the casing on the left side, so i got a slightly larger bolt and greased it up and re-threaded it by hand, worked perfect.....well today as i pulled it again to clean the egr.....i noticed where i had that new larger bolt the casing was cracked, the crack goes down about a quarted inch down the casing, should i be concerned??? the bolt still goes in and tightens but will that crack in the aluminum casing cause any harm???
Hotshot
Joined: Dec 2003
Posts: 15,369
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From: Stuttgart, Ar
It is your intake manifold. I might be tempted to take some JB weld and seal the crack as it will have a small leak there, or you could remove it and have it tigged back together. It's NOT of a huge concern, depending on the size of the crack, but knowing the characteristics of aluminum and with the heating and cooling cycles it goes through it most likely will spread over time. Just be sure that if it's welded you drill both ends of the crack to keep it from spreading OR just find you another manifold.
Elder User
Joined: Mar 2005
Posts: 526
Likes: 4
From: New Jersey
I have run into this twice @ the dealer where someone had apparently overtightened the bolts for the EGR valve. You can REPAIR the bolt holes in the intake manifold by installing a Heli-Coil thread insert which requires a little careful drilling and tapping of the stripped out bolt hole. The thread size is metric, M6X1 - if you decide to go to a parts store to get a thread repair kit bring one of the bolts to double check the thread specification. (I am on vacation this week and can't verify what the specs are on my kit in my toolbox but I am fairly confident on the M6X1) It can be done without removing the intake manifold - remove the EGR valve and cover the opening with tape before beginning the repair. The Heli-Coil insert threads are stronger than the original and if the crack is small enough it shouldn't cause any problems. If I recall these are blind bolt holes and you want to be sure that you don't drill all the way through the bottom of the hole.
P.S. - While the thread repair kits are not cheap they are much less expensive than a new manifold.
Good Luck!
P.S. - While the thread repair kits are not cheap they are much less expensive than a new manifold.
Good Luck!
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Joined: Feb 2009
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I was on the jb-weld website and it says that the max temp. is 500 degrees, and to not use on exhaust manifols and exhuast components, but i can use it on the intake where the egr valve is?...Just wanna make sure...
