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Old 04-07-2009, 12:12 PM   #1
Ools
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Unhappy Issues while swapping Please Help!

so i started with a 99 rs, and spun a bearing.

so now i'm putting in an 05 rs engine, and there are a few small differences.
keep in mind, i'm gonna try to pass smog
for one there's this copper pipe coming out the back of the newer rs engine, i'm guessing it's an exhaust bypass pipe, it's filled with black.


since there isn't one of these on the older rs engine, is it possible that i could just plug it?

or what should i do about it?

the next issue is the air line on the top of the block.

here it is on the older engine


and here it is on the newer engine


the older one is pressed in and the newer one is screwed in.

so the options are pull the pressed in one out of the old one and try to press it in the new one, or the idea i'd prefer, find a smaller hose that will fit the nipple.

here's a picture of that hose

the part on the left is what covered the pressed in fitting on the older engine.

so what do you guys think?
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Old 04-07-2009, 05:09 PM   #2
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I thought the 1st gen 2.5L motors had that pipe? It's EGR, from the driver's side head to the EGR valve. If your old motor doesn't have an EGR valve at all, then you can plug this hole. Not sure what the best choice is, that pipe is a coated steel. Not sure what the coating is.

As far as that fitting in the block, that's part of the crankcase ventilation system. That line is teed into the intake system pre-throttle body and the PCV valve. What intake manifold are you using? One for the '05 motor or your old one?
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Old 04-07-2009, 06:29 PM   #3
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Quote:
Originally Posted by fastenova View Post
I thought the 1st gen 2.5L motors had that pipe? It's EGR, from the driver's side head to the EGR valve. If your old motor doesn't have an EGR valve at all, then you can plug this hole. Not sure what the best choice is, that pipe is a coated steel. Not sure what the coating is.

As far as that fitting in the block, that's part of the crankcase ventilation system. That line is teed into the intake system pre-throttle body and the PCV valve. What intake manifold are you using? One for the '05 motor or your old one?
my old one, since i didn't want to convert to drive by wire.
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Old 04-07-2009, 06:49 PM   #4
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The EGR pipe can be plugged. The cleanest way I know to do it is to get a 1/4" pipe plug and matching tap (NPT thread), then remove and the cut the EGR pipe so you can free up the fitting. Thread the inside of that fitting and screw in the pipe plug. Lastly, put the plugged fitting back into the head and forget about it. The easiest way would be to cut the pipe off and bend it over itself to seal off most of any discharge. Totally ghetto, or temporary, but functional.

For the crank breather, you may be able to find a 1/2" hose barb with male threads that fit the fitting on the block. If so, you're good to reuse your old setup. If not, remove that fitting and have a small chunk of tubing welded to it.

Jay
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Old 04-07-2009, 09:16 PM   #5
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Quote:
Originally Posted by Storm View Post
The EGR pipe can be plugged. The cleanest way I know to do it is to get a 1/4" pipe plug and matching tap (NPT thread), then remove and the cut the EGR pipe so you can free up the fitting. Thread the inside of that fitting and screw in the pipe plug. Lastly, put the plugged fitting back into the head and forget about it. The easiest way would be to cut the pipe off and bend it over itself to seal off most of any discharge. Totally ghetto, or temporary, but functional.

Jay
i can just unscrew the pipe and screw in a plug then right?
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Old 04-07-2009, 10:46 PM   #6
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^^^ Not unless you find a plug in the bastard metric size thread they use. If you can, by all means do it. I searched McMaster-Carr, as well as some other specialty hardware outlets for the size, but never found a "plug". One thing I never looked for was a scrap head that was non-EGR. That may be the easiest yet...... DOH! Hindsight is always 20/20....


Jay
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Old 04-08-2009, 06:07 PM   #7
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thanks jay.
i fixed the pcv hose issue, now i'm stuck on the egr problem, if i do plug up the egr, will pressure build up, or will it just go out the exhaust?

someone told me i risk blowing seals if i do plug it.
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Old 04-08-2009, 07:08 PM   #8
GrundleJuice
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I think whoever told you that thought you were talking about the PCV system.
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Old 04-09-2009, 05:09 PM   #9
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sweet, so i'm safe to plug up the EGR then?
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Old 04-09-2009, 06:30 PM   #10
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Yes, plug the EGR port. All it does is provide some exhaust to be recirculated. Plug it and all will be well.

Jay
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Old 04-09-2009, 06:37 PM   #11
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^_^
thanks!
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Old 04-09-2009, 09:54 PM   #12
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I had the exact same problem as you for the PCV system. I had an 01 RS block, and put in an 05 block. I found a brass fitting that had threads for the intake manifold and barbs on the other side. Screwed that sucker into the IM and ran a tube from the block to the IM.

Are you guys sure that the top picture is an EGR tube? It looks like it's threaded into a coolant passage. I agree that it can be capped off, but I'm confused as to where it goes.
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Old 04-10-2009, 11:19 AM   #13
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It it threaded into the exhaust port on the head and goes to the EGR solenoid on the intake manifold. A picture showing the inside of the exhaust port would illustrate exactly where that hardpipe is tapped into.

Jay
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Old 04-10-2009, 02:50 PM   #14
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man, what does that do to flow inside the exhaust port?
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Old 04-10-2009, 04:19 PM   #15
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Nothing substantial..... A better question might be why would they only recirculate exhaust gasses from one cylinder in the first place?

Jay Storm
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