Leaks after !EGR ... how to fix?

[Wicked 3800 V6]

I did the !EGR over the course of the past two weeks or so (in the middle of spring / shock / more stuff). Intake side seals fine, as far as I can tell. I reused the stock bolt, part of some aluminum flashing, and some washers.
Exhaust side, similar situation -- aluminum flashing (hole drilled for bolt), reused bolt, washers under bolt .. leaked like a mofo all around it. So I pulled it off (big whoop -- my 10mm wrench). Put some red RTV on a washer both sides, stuck that to the manifold-side of the flashing, now it leaks slightly less and smells like burning RTV (I let dry for 45 mins or so). I need to fix this bi-atch. How did everyone elsemanage to get it to seal?

Not to mention I need an alignment and my steering wheel is an assload off.
-Rob

[AllTheGoodNamesAreGone]

maybe cut a peaice out of sheet aluminum or steal and drill holes though it.. slap a stock gasket in front of it.. and maybe a little bit of high temp rtv..

thats all I can think of..

~Billy

[Ted]

Is it really worth it? For something that will probably benefit you more for having then without? Anyway, just wanted to warn you if you haven't already not to remove the tubes that connect to your manifold. I broke a bolt head off in it, leaving the shank inside the manifold. Talk about a living nightmare. The way it's angled nothing can get it out.

[FirebirdGT]

http://www.zzperformance.com/zzp/pro...koff_plate.htm

[Wicked 3800 V6]

Listen, the whole EGR is already off. Makes a nice open space in the engine bay, especially when you're grabbing at your steering shaft. (not like that, perv).

The question is what will seal an exhaust leak? I have some red "high temp" silicone sealant ... is there anything stronger? I have a set of tubulars -- I may just weld over the EGR hole in those and then put the driver side one on. As for the SES, etc, that'll be another day.

Maybe a little filter on the intake manifold egr hole?

-Rob

[nikon]

<blockquote>quote:</font><hr>Originally posted by Wicked 3800 V6:
Listen, the whole EGR is already off. Makes a nice open space in the engine bay, especially when you're grabbing at your steering shaft. (not like that, perv).

The question is what will seal an exhaust leak? I have some red "high temp" silicone sealant ... is there anything stronger? I have a set of tubulars -- I may just weld over the EGR hole in those and then put the driver side one on. As for the SES, etc, that'll be another day.

Maybe a little filter on the intake manifold egr hole?

-Rob<hr></blockquote>

leave your EGR there, block off the manifold with that plate from ZZ stick a filter in the tube you pulled form your exhaust manifold....and your good to go....

[Wicked 3800 V6]

AAah. Darnit, I'm not putting it back on. I just need to know how to seal the plate to the exhaust manifold. I've got it almost all sealed, still leaks maybe 20% or so around part of the plate. I'll pull it off and put more RTV on I guess and see if it helps. On another note, I really really need an alignment ...
-Rob

[John_D.]

I had an old exhaust gasket laying around, and used tin snips to cut a piece big enough to fit under the flange. I didn't try to shape it exactly or anything like that, just made sure it stuck out all around. Then like you, put a washer on it, and bolted it down. No sealer, no leaks.

I eventually had to put it back on, due to emissions testing...

If it's a lock washer, the high side of the washer could be facing the opposite way of the long side of the flange. That could cause the outer end of the flange to not have enough pressure on it to hold tight. I think I had a flat washer on mine.

[Wicked 3800 V6]

thx John. I'm not sure about emissions just yet -- just had mine a few months ago so i'im good for about 2 years. By then we better have L36 edit!
-Rob

[Ted]

Wicked, try using some muffler mender.