Thread: Manifold EGR plug!

Gyeah. This car has been giving me more trouble lately... first the idle, then the axle, now one of the egr plugs on my header fell out on the freeway FOR THE SECOND TIME . So now I have a nice hole pointing right at my coolant hose and I'm about to go on a 400 mile trip in 2 days.

Unfortunately, the last time it fell out I had no quick solution and I had to use JB weld and a bolt that was too small (tried pretty much every threaded metal object the hardware store had). That lasted a few months and is what just came out.

Does anyone have any good suggestions? I know most of you are going to say bring it to a shop for welding, so I am just sort of hoping someone has some wild idea that will be faster/cheaper. Plus I don't know if shops will weld EGR plugs on anyone else know? It is the TOP egr plug by the way not the front one.

Just shooting for any ideas. I don't think I have time to get anything on the internet as I have to leave in a few days.

Thanks for your input!

On the stock manifold, where the O2 sensor bolts in, you should be able to remove the bung that the o2 sensor screws into, I think that will fit into the hole on the top right of the header, then you can find a bolt that is the proper diameter and thread pitch (the same as the o2 sensor) at home depot, and plug it up like that maybe?

Hmm, on my manifold (which was the JDM tubular header), that bung is welded in, so that doesn't really make it any easier than pulling the mani and bringing it to a shop.

oh ok. on the usdm the bung screws out.

is the fat o2 sensor the same thread? if it is you can plug it with an old o2 sensor if you have one laying around?

I'm pretty sure that JB Weld is only good to around 500 degrees, which is why it doesn't last too long. See if you can find someone around you with a USDM exh. manifold. Loads of people have them laying around usually cuz they don't want to throw out a perfectly good manifold just incase they ever need it.

600 degrees, but it lasted quite a while, so I am thinking it didn't melt but the expansion/contraction of the mani in this cold weather probably cracked it. Edit: Sorry I misread. Maybe I can find a USDM mani around here, good idea.

Hmm, the 02 sensor might be an option, though I don't have one of those either, but maybe I can find one around somewhere.

I didn't mean to use the manifold, I just ment to remove that bung that the o2 sensor goes into, then you can just plug it with a regular o2

Actually I think I might see if the JDM header will bolt up but it seems pretty unlikely. Maybe I'll get lucky, they are both 4 - 2.

Well, problem solved. For the record, JDM tubulars do NOT mate up to the megan downpipe

I figured a shop would be easiest and best since I had no other resources to fix it. Exhaust shop! They were able to find a plug from the next door advance auto that fit in the hole and were able to weld it in without even removing the manifold. Charged $40, not super cheap, but hey, it's fixed. I think they ended up using a small engine block plug or something of that nature. Even they had nothing that fit the threads.