After reinstalling the intake manifold I got the egr tube screwed back in to the manifold and then in the process of bolting down the plate that holds the egr valve the passenger side bolt head broke off. The bolts seemed to be in rough shape and i had a feeling they were gonna break. It’s stuck out about a 1/4 in from the Intake manifold, trying to get it out with vice grips was unsuccessful. Gonna try and drill it out with a left hand drill bit or an easy out. But let’s say I’m not able to get this bolt out, is there anyway I can plug this hole in the intake manifold and just delete the egr? I pretty much refuse to take the intake back off just for this stupid egr valve.

 

Actually, an egr valve does help keep the combustion chamber temps down. there are other options available for repairing those busted bolts. Like just drilling it out and inserting a thread replacement like a heli-coil or other type of insert. Some of these rust prone areas could be helped with using a stainless bolt or stud.

 

Or, if you have a buddy that has a portable electric welder, weld a nut to what is sticking out, and use that to extract it. Buy new bolts.......