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Discussion Starter #1 (Edited)
Hi,

I'm a new member and would like to know what would be the easiest way of replacing the upper EGR tube seal (blue rubber seal). This seal is between the upper manifold the upper EGR tube.

I have a vacuum leak from a recent tuneup job in which the techs failed to seat the seal properly.

From what I've read so far, there are 2 options to replace upper EGR tube seal:

1) remove the upper manifold or,
2) remove the cowl (to get to the EGR valve and remove the upper tube)

Both seem to require a quite amount of work so I'm interested in getting ideas on a faster way of replacing the seal w/o taking option 1 or 2.

I fear there are no other options but am crossing my fingers.

Thanks,
d_bruce
 

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Discussion Starter #2 (Edited)
I got it resolved; removed the plenum (upper manifold) and cowl (not necessary to remove the cowl for the job I did).

I thought that I could remove the cowl and just replace the EGR gasket and seal. That didn't work because I couldn't reach the EGR. So, after the plenum was off, I slid the seal onto the end the of the EGR upper tube and put the plenum back in place.

I think it was much easier when 2 ppl are working on it. The only issued I had was loosening one of the bolts, when removing the plenum, that holds the support bracket (near the alternator) on the left side of the engine. The space was a bit tight but a long 15mm combo wrench gave me some leverage outside of the tight space.

The gasket on the plenum was fine but I replaced it anyways.

blue seal: $9
Gasket: $17
Time: 4 hours (had to go pick up a 15mm wrench and gasket); I could have shaved off another hour if I hadn't removed the cowl.
 

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i know i'm a little late but, it's a 10 minute job. no need to remove the cowl or the plenum.
lay across the top of the engine and look down through the opening where the trans dipstick tube comes out. from there you can see the 2 tube-to-EGR flange bolts. using a 1/4" drive 8mm flex socket, an 18" extension and ratchet, you can remove the flange bolts. then you can remove the tube.
once you replace the tube seal AND the flange gasket, you can reinstall the same way you took it out. make sure the tube stays fully inserted in the plenum as you tighten the flange bolts.
the flange gasket is also a possible leak point and should be replaced anytime the tube and/or plenum is removed.

sorry for the late reply.
 

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Discussion Starter #4 (Edited)
No worries, fnkychkn. I thought I had posted the question in the wrong category :)

Despite the unnecessary efforts to remove the plenum and the cowl, I did learn a lot about whats under the hood. When the EGR valve goes out next, I'll definitely remember to buy that 18" extension to make things a little easier.

Thx!
Cheers
 

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i know i'm a little late but, it's a 10 minute job. no need to remove the cowl or the plenum.
lay across the top of the engine and look down through the opening where the trans dipstick tube comes out. from there you can see the 2 tube-to-EGR flange bolts. using a 1/4" drive 8mm flex socket, an 18" extension and ratchet, you can remove the flange bolts. then you can remove the tube.
once you replace the tube seal AND the flange gasket, you can reinstall the same way you took it out. make sure the tube stays fully inserted in the plenum as you tighten the flange bolts.
the flange gasket is also a possible leak point and should be replaced anytime the tube and/or plenum is removed.

sorry for the late reply.

I know it's years later but can I get by with a 3/8 drive extension
Thanks not sure where to get a 1/4 drive on short notice
 

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I know it's years later but can I get by with a 3/8 drive extension
Thanks not sure where to get a 1/4 drive on short notice
again, sorry for the late reply.
haven't tried a 3/8 drive for this application. not sure there would be enough clearance at the EGR valve end between the bolt head and the tube. maybe with a deep socket???
 

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Was able to borrow a 1/4" extension from a friend at work.
I"ll give it a shot tomorrow.
The repair shop told me they think the intake manifold is melted but the only thing that I see is part of the outer flange (if you would) of the manifold is broken off. ( the part that sticks out where the egr tube goes into) I'll let you know how it goes. The manifold is a dealer item, I'm told it's about $1800.
Thanks once again and have a great rest of the weekend.

Joe B ::smile::
 
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