Plugs for Intake and Exhaust Manifolds

[bylzebub]

Just got my truck back after installing my new headers and exhaust. The only thing missing is a plug for the EGR, my exhaust guy had a plug for the O2 sensor. My old header was completely rusted and I couldn't get the old EGR pipe plug out. I ended up cutting the tube and plugging it with JB weld for the time being.

 

So I need a plug for the new one anyway, and while we're at it I'd like to plug the intake side as well where that plastic "tree" piece comes off and has 3 vacuum line attachment points. I don't know the name of it or what it when too since I deleted those lines on my Weber 32/36 install.

 

Let me know if these plugs are a known thread and size. I'll get pictures tomorrow if this doesn't make sense. Its a pacesetter header if that matters.

 

On a side note, where is the proper place to install a Fuel/air sensor and gauge?

 

Thanks!

[Lockleaf]

Fuel/air sensor is just a sophisticated O2 sensor. It goes where the O2 was. Install gauge wherever convenient. 4x4 720s had gauges in the center console. If you aren't using those, you could put the gauge there (assuming it's a standard 2 3/8ish size gauge). Also if you are lacking the factory tach or clock, you could likely find a way to install your gauge in one of those openings.

 

You can use standard pipe thread to plug your vacuum switch on the intake. I believe it's a 1/4 pipe plug. These will not thread down all the way or sit flush, but they will thread in and seal without damaging the threads.

 

Not sure about egr size.

[datzenmike]

Header? The stock exhaust between head and down pipe is better called an exhaust manifold to differentiate it from an after market thin tube 'header'.

 

 

Thermal vacuum valve T V V is it's name. Located just in front of the carb? Almost certainly it will be a metric thread.

 

The EGR valve bolts on to the intake so you would need to make a cover plate and gasket.

[bylzebub]

Well I got one out of the two plugs found and installed today. Turns out the internet knows everything. After a bunch of searching I came across a forum with a guy that stated late 2000 VW Touareg and Audi SUVs have oil drain plugs that fit the proper threads for the ERG hole. That happens to be M24 x 1.5. I called 3 parts shops looking for a plug and one specialty fastener store, nobody had anything 24mm, 22 was as close as I got. So after calling my local VW dealership I tracked down the plug. Good news is it does fit, bad news is it cost me $20 for the plug and $4 for the freaking crush washer. Dealerships are the devil.

 

 

The brown sludge is just copper anti seize so that plug comes out easy if it needs to. I forgot to measure how long it is but less than an inch. Best of all it looks like it was made for the header.

 

 

So header was the correct term, sorry Mike, those are the pacesetter headers, my manifold rusted out. Actually I just got the exhaust all finished too, deleted the cat and went 2 inch the whole way plus the biggest muffler I could get to make it as quiet as possible. Truck sounds pretty amazing now. I'll update here when I find a plug for the T V V and EGR block plate.

[Lockleaf]

Egr block off plate.

 

 

I made this one by tracing the egr gasket. If you have a drill and a grinder, it's not hard to make one. This is on a z series intake manifold. It's on the z22 I'm finishing up in my 510.

 

This is in place of my TVV valve on the same intake.

 

 

I realize it may not be the prettiest, but it seals tightly and doesn't leak. It is a 1/4 inch pipe plug. I did this same exact thing to a z24 about 4 years ago on my 4x4 720 and have had no problems from these plugs at all.

[Lockleaf]

I think I lied. I think it's a 3/8s npt plug. I think the others I have are 1/4. I can confirm that TVV on some datsuns were NPT by the mid 70s, at least according to specs listed on the datsun 1200 wiki.

[Lockleaf]

Nissan 720 vacuum switch is part number pvs90 from Standard Motor Parts. Specs on it show 3/8-18 NPT thread pitch.

[bylzebub]

Nissan 720 vacuum switch is part number pvs90 from Standard Motor Parts. Specs on it show 3/8-18 NPT thread pitch.

 

Sweet, thanks for the exact pitch. Is that a hardware store option or a Nissan parts department thing?

[Lockleaf]

I got mine at the auto parts store