I was doing the egr removal for my 96 cummins 12v when I broke one of the bolts that holds the egr pipe on the exhaust manifold. Now I have a broken bolt on the manifold and a 1 inch hole where the egr pipe sat. Does anybody know how to fix this permanently with out taking the manifold out, drilling out that broke bolt and rethreading it. I am okay with that broken bolt because it broke off flush with the manifold. I just want to plug that 1 inch egr pipe hole permanently. Would I be able to weld a steel plate on the cast manifold or could I thread that 1 inch hole and run a short bolt down it? Pretty frustrated so any help would be great!



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Thread it and bolt it.

 

I should tap the 1 inch egr hole and run a bolt down it

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Make sure you get any metal particles out, you don't want that crap going through your turbo. I would be tempted to take off the turbo and start it for a couple of seconds to blow it out. Get some ear plugs!

Dame smog stuff fights all the way to the end.

 

Do you guys know how much pressure is inside the manifold. I got a cap on it just wondering if it will blow off?

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I ended up tapping that hole which is only 11/16 and threading a short pipe plug in it. The threads were pretty shallow but it threaded in there nice and tight and so far its holding up! Thanx guys form the input!!

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