I've got the upper intake off while I'm doing the injectors on the pass side. I'm also going to gut it.

The intake is almost completely plugged with thick black oily goop. I assume this is blowby. Is this normal? What would be causing so much? It's any wonder it can breath at all being the S intake and then with all the goop.

Any thoughts?

I'm in the process of trying to clean it up. What a mess!

Dave

It's a composition of oil from your crankcase venting through the CDR and into the intake and soot from the exhaust gas that's dumped into your intake to assist in starting a cold engine. If you don't block the EGR, it'll continue to accumulate. Please don't view this material with such distain; it doubles as a fine conditioner for the neighbor's poodle that craps in your yard.

its from the egr. all the soot and crap that is recirculated fromt the exhaust to meet "emmissions" standards.

I did mine recently and it had a small amount of this buildup as well.

143,000 miles of egr working as intended. Removing the webbing should let it go on through instead of building up.

get a frost plug....that will fix the problem

get a frost plug....that will fix the problem

I've read about blocking the EGR by using a frost plug. What exactly does that mean? What other ways can the EGR be blocked off on an S intake without setting a code?

I've managed to clean out the gunk....what a mess!

There is also lots of goop in the lower intake. Any tips for cleaning that up? I take it I won't want that stuff getting down into the intake ports.

Thanks,

Dave

You will need to take it off.

I got an F intake to replace mine. If you look at it you will see that the exhaust is running through the intake even if you block the hole, making the intake air very hot and thin.

Jam a 45 mm frost plug into the EGR tower in the lower intake....needs to be installed inside the 'mystery gasket' for best fit...

Jam a 45 mm frost plug into the EGR tower in the lower intake....needs to be installed inside the 'mystery gasket' for best fit...

Will this cause any codes?

By the sound of it, this will not completely block the EGR. I don't necesary need/want a complete swap to a F intake but if I can do something simply that will improve the way my truck runs, then I'm all for it.

Thanks,

Dave

I have no codes from it.....

Why won't it completely block off the EGR?

You are still going to have gasses come up into the tower but that is where they will be blocked...

If you dont unhook the wires there will be no codes, I unhooked the vacuum line (plugged it) from the EGR and no codes as far as the computer knows its working

I'm just going by what David Phillips said above your post. I've tried to read up on this whole process of blocking off the EGR but I get confused evertime and just end up saying forget it. Then I read your post above just jamming a frost plug in there and it sounds simple. Maybe there is several different things going on with the EGR and bypassing it or blocking it and I'm getting confused.

Is it by chance a case of the older trucks vs. the new trucks? Yours is a 94 and min is a 98. Has something changed that will give me problems that doesn't give you problems?

Thanks,
Dave

Jam a 45 mm frost plug into the EGR tower in the lower intake....needs to be installed inside the 'mystery gasket' for best fit...

Block it at the heads or you will still have "crossover" through the lower intake. Either 6.2 J intake gaskets or nachine in a round hole and add 2 plugs.

Other notes: http://www.kennedydiesel.com/airboxmods.html

Block it at the heads or you will still have "crossover" through the lower intake. Either 6.2 J intake gaskets or nachine in a round hole and add 2 plugs.

Other notes: http://www.kennedydiesel.com/airboxmods.html

So will jamming a frost plug in there do anything?

Thanks,
Dave

Yes - jamming a frost plug in the tower stops EGR gasses from getting to the valve itself....

Like Kennedy said (and I already said it too) is that the gasses will still get up to the intake tower....it is not a perfect fix but it is easier than taking off the lower manifold and changing intake gaskets IMO...

DSG sells the frost plug as an EGR blocker....look it up...