Trying to get it right-

[Turdle]

Well it looks like the best thing to do would be to start a new egr tube-the hole at yellow arrrow is huge--
Eric (techieman33) was very kind and left me an extra tube-

If you look where the red arrow points you'll see a larger tube used as a sleeve-
I'm gonna cut it off and try to get the opening cleaned out to accept the new tube-then weld up around it-
As you can see I have the upper neck angle bent in pretty well--


Black lines show where I plan to cut--sound good?

Then I'll need to cut the extra tube off and weld that hole shut-which is what started this whole mess-
My egr tube was "working fine" even though it had an extra capped off tube sticking out-I should have left it ugly--

 

[Turdle]

OK
DPFE
Differential Pressure Feedback EGR

From my experimenting and reading--
The DPFE sensor is merely that-a differential sensor-

there are 2 tubes on the egr tube going to it, in between each of these tube "nozzles" on the egr tube is an orifice--
it is a thick metal bushing with a small hole. this causes a pressure difference between the 2 "nozzles" when the exhaust gasses pulse through.
To satisfy the DPFE sensor-all that is needed is a differential between the 2 nozzles.
If you look at the new duplicated setup, which was working just fine on my truck-you'll see I used 2 egr tubes to make one-and in doing so I now have 2 orifices an 3 "nozzles"--lol
laugh now for a bit--

ok now-get over it for a minute and try to listen-
This is needed to connect to my Typhoon intake manifold-
I"M KEEPING MY EGR!!!
I had the tubes connected in every combination imaginable-with the extra "capped off " with a small chunk of silicone hose and a bolt in it.

As long as there is a pressure difference between the 2 hoses-all is good--No CEL

Don---any clues from this?

Back to the fix--

After debating about cutting this fine 100.00 egr tube---
and nobody to say no,
I turned to my buddy Mr Sawzall--


Here is where I am now-I had to sand the heck out of the inside of larger tube and outside of the egr tube-take my word for it it is slid in about 1/2" and is tight-I may need to adjust the length a bit though.
The bottom weld was wire welded by the exhaust shop I use-I think I'll go back there tomorrow and have him weld it up for me again. It is just a small exhaust pipe--you know.

Taking off the 3rd tube started all this mess--
I will use the top 2 for functions-and cap off the lower one. You'll never see it.:

 

[CDW6212R]

Interesting, how large is that orifice hole? Obviously not much gets through it yes?

Very little is seen of the old EGR system, what is the big improvement with this odd tube design? The older system may be better for odd high performance combinations ie; ours.

 

[Turdle]

Interesting, how large is that orifice hole? Obviously not much gets through it yes?

Very little is seen of the old EGR system, what is the big improvement with this odd tube design? The older system may be better for odd high performance combinations ie; ours.

The orifice passage is about 5/16" to 3/8" .

I like this system better actually-it is all external, and is less "mechanical" in that it doesn't use a "position " sensor and a linkage that must actually change position, and even if those mechanical actions occur-there could be a weak egr pulse.
This system actually senses egr pulses-and is much simpler--to me anyway.

 

[CDW6212R]

Okay then, you are telling me to make room for a weird pipe on my headers later. Thanks,

 

[Turdle]

Here is the orifice-just for understanding--

 

[CDW6212R]

That will flow plenty of air. I see custom unit like that in my future, cut and welded together to fit. Thanks for the example.

 

[Jakee]

This EGR tube is the most expensive and has the most hours to make; EGR tube I've ever laid eyes on.

 

[Turdle]

This EGR tube is the most expensive and has the most hours to make; EGR tube I've ever laid eyes on.

One of a kind!:

 

[techieman33]

One of a kind!:

Glad to see you made use of my egr, otherwise it probably would have sat around doing nothing.

 

[rocket 5979]

Jon, I assume that you are going to make that throttle cable bracket yourself instead of sending your TB to me? Good luck with it.

 

[Turdle]

Jon, I assume that you are going to make that throttle cable bracket yourself instead of sending your TB to me? Good luck with it.

I am probably going to end up sending it to you, But I want to give it one more crack--

 

[Turdle]

My Son Bryan is home for awhile-so we are doing some much needed fixes to his car-one of which was a new muffler. While there-I had the guy cut off the extra nozzle-and weld up the EGR tube.
I'll be back to this-but for now I'm doing the "dad" thing for a day or 2.

 

[Xan]

My Son Bryan is home for awhile-so we are doing some much needed fixes to his car-one of which was a new muffler. While there-I had the guy cut off the extra nozzle-and weld up the EGR tube.
I'll be back to this-but for now I'm doing the "dad" thing for a day or 2.

Shouldn't he take after his dad and be able to fix anything too? Nice way to sneak in still working on your stuff

 

[410Fortune]

$100 for an EGR tube? Holy moley!!

running yet?

 

[Turdle]

Not Fair!!! You have help--good help

I'm on project Tempo-Bryan has my Grandmother's 91 Tempo with 40k on the clock--but it needs some attention.
So far we have replaced the valve cover gasket and grommets-new muffler (Grandma had installed a lifetime muffler-but she's dead now and it fell off), new tires, oil change, radiator flush,fuel filter and spark plugs.
Now we are cutting holes in the doors for his speakers. It will need some wooden spacers to clear the windows-so this will take the rest of the day.
We are also installing a head unit I got from Dan, plus an amp and subwoofer. Nothing great-but he'll have some better than stock sound.
He's looking for a nicer car-but this will be his daily beater.

The brakes squeak-so we need to look them over.
Then we are sanding the peeling window pillar trims and painting them black again, and a day is planned to go to the junk yard for some wheel center caps-

The Mounty is on hold for a minute.

 

[Xan]

Not Fair!!! You have help--good help

I'm on project Tempo-Bryan has my Grandmother's 91 Tempo with 40k on the clock--but it needs some attention.
So far we have replaced the valve cover gasket and grommets-new muffler (Grandma had installed a lifetime muffler-but she's dead now and it fell off), new tires, oil change, radiator flush,fuel filter and spark plugs.
Now we are cutting holes in the doors for his speakers. It will need some wooden spacers to clear the windows-so this will take the rest of the day.
We are also installing a head unit I got from Dan, plus an amp and subwoofer. Nothing great-but he'll have some better than stock sound.
He's looking for a nicer car-but this will be his daily beater.

The brakes squeak-so we need to look them over.
Then we are sanding the peeling window pillar trims and painting them black again, and a day is planned to go to the junk yard for some wheel center caps-

The Mounty is on hold for a minute.

Only 40k on the car? it can't be in that bad of shape its still a tempo not a chick magnet but it sounds like a ok car for a while. Let me know if you need any more stereo stuff i got alot laying around

 

[Turdle]

Only 40k on the car? it can't be in that bad of shape its still a tempo not a chick magnet but it sounds like a ok car for a while. Let me know if you need any more stereo stuff i got alot laying around

Hmm, what you got?

 

[chriswells78]

I need a car like that to make into a mini-stock race car for my local track. LOL

 

[Xan]

Hmm, what you got?

I got a infinty kappa perfect 10" (hmm i might swap this back out) its in a box made for the mounty so the bigger of the fold down seat folds.
If i swap that back in i'll have 2 12" bosten G2s in a double box
I got a kicker comp vr8
and a pair of cerwin vega 6 1/2"s

i got the factory amp and sub out of the mounty : haha