240 EGR Intake Port Blocking / Blanking Plate

For LH-Jet / EZK116 1991.

I have yet to find a ruler and measure the intake port EGR union.

I have the exhaust manifold EGR plug machine bolt and a copper washer.

Yes, I've searched the forums here and afar about EGR delete.

Else, some 14 gauge steel and washer with a gasket section making seal on the intake port manifold.

Thank you!

I made one on my 3d printer out of ABS and used it and the gasket to seal to the intake manifold.

Hi and thank you,

Would you have a cad file or drawing you used to create your 3D print of a EGR blocking / blanking plate, please?

The dimensions, bolts hole on center, and so forth.

Could you attach you CAD / drawing file here or send or link, please? I don't own a 3D printer yet maybe have the plate fabricated.

Else, a soup or frozen juice lid, maybe two stacked, and Permatex Red RTV with washers to secure the lid metal and secure it under the EGR flange bolts on the intake. As a temp fix.

Several responses have said cutting the EGR pipe intake manifold end, and welding it closed.

I'd like a blocking / blanking plate.

Thank you,

Bruce

TheMenaceSD said:

I made one on my 3d printer out of ABS and used it and the gasket to seal to the intake manifold.

Click to expand...

Let me see about getting the file. I know people have cut the pipe and used a nickel to cover the hole and bolt it down.

Volvo sells a block off plate kit for the EGR port on the intake but it ain't cheap.

https://www.tascaparts.com/oem-parts/volvo-service-kit-271658?c=bD0xJm49U2VhcmNoIFJlc3VsdHM%3D

It comes with #53, 54 & 55.

I used the EGR stuff as model and cut a matching gasket and cover plate from 1,2mm steel. Thicker would probably have been better, but it has been working good so far.

Volvo LH-Jet US EGR Blanking / Blocking Port

Thank you. Art B. posted on a service kit yet is listed as NLA. On the Genuine Class Parts sales part manual, something like "shall not return" or something

Different diagram.
<img src="https://www.volvopartswebstore.com/images/parts/volvo/fullsize/GR-58889.jpg">

How do you know the kit comes with #53, 54 & 55. Did you buy this kit?

So I'll verify if whether the LH-Jet EGR blanking or the cold start injector flange.

Your diagram:
<img src=https://www.volvopartswebstore.com/images/parts/volvo/fullsize/GR-67916.jpg>

hiperfauto said:

Volvo sells a block off plate kit for the EGR port on the intake but it ain't cheap.

https://www.tascaparts.com/oem-parts/volvo-service-kit-271658?c=bD0xJm49U2VhcmNoIFJlc3VsdHM%3D

It comes with #53, 54 & 55.

Click to expand...

Cold Start Injector Blanking Plate?

If you look on this page:

https://parts.volvofw.com/p/Volvo_1991_240/Service-kit/42910962/271658.html


I'll ring the dealership ....

There is a diagram of the kit, and the parts look like a plate for the cold start injector port.

hiperfauto said:

Volvo sells a block off plate kit for the EGR port on the intake but it ain't cheap.

https://www.tascaparts.com/oem-parts/volvo-service-kit-271658?c=bD0xJm49U2VhcmNoIFJlc3VsdHM%3D

It comes with #53, 54 & 55.

Click to expand...

I didn't buy the kit but the parts catalog shows what parts come in the kit. I verified that the gasket in the kit is the same one used for the EGR pipe.

The kit appears to be available. Check with your local dealer to see if they can order it.

Volvo part# 271658 prolly NLA allslow ...

I rang up the dealership in Lynnwood, WA.

The parts guy indicates he cannot find the kit available as far as his Volvo Cars part network can see.

I don't want to destroy the components like to cut up the second EGR pipe to make a sealed flange for the EGR intake port. If I had my parts collection here, I'd be able to preserve EGR with not so rusty EGR pipes and a newer or unused EGR valve.

I'll call a few more dealerships. Yet what is available with OEM Volvo parts and what is *actually* available are not the same. At least we have some support for RWD models.

Thank you.

hiperfauto said:

I didn't buy the kit but the parts catalog shows what parts come in the kit. I verified that the gasket in the kit is the same one used for the EGR pipe.

The kit appears to be available. Check with your local dealer to see if they can order it.

Click to expand...

CAD model / drawing please, sir!?!?

Like to keep the components and not to cut up the second EGR pipe to make a sealed flange for the EGR intake port. If I had my parts collection here, I'd be able to preserve EGR with not so rusty EGR pipes and a newer or unused EGR valve. Well, maybe.

CAD model / drawing please, sir!?!?

TheMenaceSD said:

Let me see about getting the file. I know people have cut the pipe and used a nickel to cover the hole and bolt it down.

Click to expand...

kittysgreyvolvo said:

Could you attach you CAD / drawing file here or send or link, please? I don't own a 3D printer yet maybe have the plate fabricated.

Else, a soup or frozen juice lid, maybe two stacked, and Permatex Red RTV with washers to secure the lid metal and secure it under the EGR flange bolts on the intake. As a temp fix.

Click to expand...

It's not a precision fit part, so you can make one if you have a hacksaw and a vice. Start with a suitable small metal plate, such as: https://www.homedepot.com/p/Steel-City-4-in-Square-Metal-Electrical-Box-Flat-Cover-52C1-50R/205124442, or look for nailing plates in hardware if you want something thicker.

Smear the EGR mount on the intake manifold with some exhaust soot, press a clean sheet of white paper against it, and rub to create a template. Center-punch and drill the metal plate to match, then cut to rough size and smooth with a metal file.

Thank you. I do not have all my tools here so fabrication is a problem.

Thanks.

bobxyz said:

It's not a precision fit part, so you can make one if you have a hacksaw and a vice. Start with a suitable small metal plate, such as: https://www.homedepot.com/p/Steel-City-4-in-Square-Metal-Electrical-Box-Flat-Cover-52C1-50R/205124442, or look for nailing plates in hardware if you want something thicker.

Smear the EGR mount on the intake manifold with some exhaust soot, press a clean sheet of white paper against it, and rub to create a template. Center-punch and drill the metal plate to match, then cut to rough size and smooth with a metal file.

Click to expand...

EGR Blanking / Blocking Parts 200 1991

What may work. Can't find my ruler, yet the images help.<br />
<br />
Made a terrible tracing of the old, stiff gasket. Complete eye-ball peering into the laptop display.<br />
<br />
Aluminum plate may be a bit too wide, yet the machine hex screws holes about line up. Maybe be some file action. The alloy is quite hard.<br />
<br />
Got from Walmart online. The piece is for:<br />
<br />
1pc Replacement For Land Rover Discovery 3/Range Rover Sport TDV6 EGR Removal Blanking Plate Kit $15.15/EA Qty: 1 <br />
<br />
Link I used, and several same pages for sale. Copy and paste link or the description into a Walmart search.<br />
<br />
https://www.walmart.com/ip/1pc-Replacement-For-Land-Rover-Discovery-3-Range-Rover-Sport-TDV6-EGR-Removal-Blanking-Plate-Kit/1174379708<br />
<br />
I bought this kit in case I I restore EGR with a new EGR valve and piping.<br />
<br />
The pieces at 900px wide. Images are larger on BrickPix.<br />
<br />
Bolt to seal the exhaust manifold EGR hole. Sand and tap thread. Use nickel anti-seize. Forgot it is way smaller than the 02 sensor thread like on K-jet.<br />
<img src='https://brickboard.s3.amazonaws.com/brickpix/14152.jpg' width='900'><br />
<br />
Copper washer used with hex bolt to seal exhaust manifold EGR port.<br />
<img src='https://brickboard.s3.amazonaws.com/brickpix/14151.jpg' width='900'><br />
<br />
Hope about line up with my terrible EGR gasket trace and the plate. May need to file each hole towards the center.<br />
<img src='https://brickboard.s3.amazonaws.com/brickpix/14154.jpg' width='900'><br />
<br />
<br />
<img src='https://brickboard.s3.amazonaws.com/brickpix/14153.jpg' width='900'><br />
<br />
<img src='https://brickboard.s3.amazonaws.com/brickpix/14155.jpg' width='900'><br />
<br />
Bolt hole compare with gasket trace and p;ate.<br />
<img src='https://brickboard.s3.amazonaws.com/brickpix/14156.jpg' width='900'><br />
<br />
May get the EGR gasket anyway.<br />
<img src='https://brickboard.s3.amazonaws.com/brickpix/14157.jpg' width='900'><br />
<br />
KIT baggie.<br />
<img src='https://brickboard.s3.amazonaws.com/brickpix/14158.jpg' width='900'><br />
<br />
Kit bits.<br />
<img src='https://brickboard.s3.amazonaws.com/brickpix/14159.jpg' width='900'><br />
<br />
MAXIMUM NEGATIVE PRESSURE (vacuum) in the Air Intake Manifold. For improved emissions and fuel economy!<br />
<br />
My 1992 with LH-Jetronic 3.1 burns cleaner includingf NOX when last checked. Not by much!<br />
--<br />