ebay header fitment issues (EGR)

[markmdz89hatch]

So I searched around and didn't find much other than a few random responses, but nothing definitive.

Obviously, as everyone else has discovered, the ebay header has a male bung for the EGR, yet 99% of the time when you back the nut off the egr tube, the damn nipple backs out of the manifold instead of the nut backing off the nipple.

Of course I am delusional and think I can get the nut off so I proceed to mangle the nipple with a pipe wrench while trying to remove it. Then I get pissed, grab a hack-saw and cut the nut right off.

As it stands right now, I have the header just resting in place, and my brother decided to drop by and "help" while I was going to grab some grub for my wife and kids. His "help" was to try to remove the whole EGR pipe so I can replace it entirely, then he too got pissed, and took a hack-saw to the other end of the EGR pipe (not good).

How in the bloody hell do I get to the nut on the back of the EGR pipe under the intake manny? I don't have the patience or time this weekend to remove the intake manny, so has anyone come up with some neat trick to loosening that nut without tearing the motor down at all?

Little help please...

 

[nemisish20]

That is for a FSZE engine. You will need to switch the intake manifold and egr tube i have both you can buy. $140 shipped. Can send you pics.

 

[nemisish20]

Oh youre local to me. I have an MP3 in my driveway i just did a FSZE swap to and i have all of the EGR stuff. Its simple to get to the EGR nut. Use an adjustable and get the car in the air. You can squeeze your arm through and crack it loose. Use PB blaster or something similar.

 

[markmdz89hatch]

where in CT? I really need to learn the different engine designations, as I have not a friggen clue what an FSZE is, or what I have in my car, nor the difference between all of the variations.

 

[njaremka]

he doesnt know what he's talking about. well, mostly.

you will need a new egr tube. dealer should be able to get one for you. just tell him you have a 2.0l protege.

to get the nut out of the manifold, you just need to use an adjustable crescent wrench. you may need to remove some of the intake piping in order to get better access, but it is possible. just dont cut anything else out of the way!

to get the header and egr tube to line up, make sure the tube is installed onto the manifold side first. install the nut, but dont tighten it down all the way. leave it a thread or two loose so that you dont have to try and line it up later. then, there is a bracket on the side of the engine, where the tube wraps around the side of the cylinder head. leave that bracket off while trying to line up the tube. then, when you are ready to install the header, get the egr tube started onto the header connection BEFORE you try to slide the header onto the head bolts. it may be a little difficult, but it should get started. again, leave this nut loose, but started. last, get the header onto the head studs and start threading the header bolts into the head. last thing will be to connect the exhaust to the header.

that should get you going. its a difficult task, but not impossible. just make sure you take your time and DON'T CUT ANYMORE PARTS OUT OF THE WAY!!!

the FSZE is the engine designation for the japanese 2.0l engine.

 

[nemisish20]

The header he has has a male EGR fitting.

The mp3 header has a female EGR fitting.

His ebay header is the exact same header that came with the JDM engine that my customer got delivered to me. I ran into the same issue with the EGR. It has a wierd angle.

If his header is the male fitting he needs to either send the header back or change the intake manifold that uses the like 30 degree angled egr bung and use the JDM EGR tube.

Im in West Haven

 

[njaremka]

The header he has has a male EGR fitting.

The mp3 header has a female EGR fitting.

His ebay header is the exact same header that came with the JDM engine that my customer got delivered to me. I ran into the same issue with the EGR. It has a wierd angle.

If his header is the male fitting he needs to either send the header back or change the intake manifold that uses the like 30 degree angled egr bung and use the JDM EGR tube.

Im in West Haven

um, nope. the stock cast exhaust manifold has a female threaded bung, into that threads a nipple, and the egr pipe threads onto that. the JDM exhaust is a completely different beast.

take a look at the diagram in the attached page from the parts manual.

 

[markmdz89hatch]

um, nope. the stock cast exhaust manifold has a female threaded bung, into that threads a nipple, and the egr pipe threads onto that. the JDM exhaust is a completely different beast.

take a look at the diagram in the attached page from the parts manual.

This is correct. Many have posted, and clearly think, that the stock EGR has a male end, and should (obviously) then thread into a female bung on the stock manifold, or aftermarket header.

...what I discovered (the hard way) is that most of those that think this, do so because when you back the nut off the EGR pipe, the nipple that's threaded into a female bung on the stock manifold backs out with it. Not good, and in many cases (mine included) the nut is corrosion welded to the nipple, so you're ass'd out on removing the nipple (hence the cutting and getting pissed off) due to lack of patience.

I did the header install nearly spot on to what nj outlined, and (obviously with the exception of the EGR woes) everything went as smoothly as can be expected.

What I did to get around replacing the EGR pipe all together was find a compression fitting (nut) with the proper thread (I believe 1/2 FPT) for the male bung on the header (basically the same stock fitting that I cut off the stock EGR pipe). Slip the nut on the EGR pipe, then used a pipe flaring tool to flare out the cut end and viola! Because I lost about 1/2-3/8" of EGR pipe length, and the fact that the aftermarket header does not locate the bung exactly where it needs to be, I had to loosen the bracket that holds the pipe to the side of the block, and very gingerly bend the pipe just enough to line up to where it needed to be. Started threading the nut on the header bung, get the header on the two manifold studs, hand snugged all of the manifold/head bolts, then finished tightening the EGR pipe nut. Tightened down the flange bolts/nuts, installed the donut gasket at the end of the header, connected the exhaust, tightened down the spring bolts, then just for good measure I used RED rtv gasket maker/sealant around the back of the nut on the end of the EGR pipe.

Started her up, no leaks (except for at that damn donut), and watched the header go from a nice polished near chrome to a nice shiny brassy color. That was pretty damn cool.

I still want to replace the EGR pipe with an uncut one, but it all works well enough as it is until I can build up the patience and hear how-to stories of how to loosen the fitting on the back of the pipe attached to the intake manny.

 

[Crash5291]

Wonderful info guys thanks,
My question is, does anyone know the right ball flange/flare size to use to mate with the header? thanks

 

[allmtrp5]

i got the same header on mine.. put it on fit was good then i ran into the same issue.all i did was stick i flat head screwdriver in the egr tube and bend it back till it all lined up nice..ill will post pics.(drinks)