How to: Port a jdm 3sgte head for egr write up (ca residents) :)

[jaydog82]

Ok so i could not find a write up on how to port a jdm 3SGTE head for egr, so i will I figured i would compose one as I do mine.

I have not done this before, so if anyone has any useful info please add it.

I know that the general consensus is to remove the egr, but if you are in CA that is a little harder to get away with. The smog shops perform a egr functionality test and it is just better to have everything working.

I followed the egr porting through the head and it looks like 3 holes + 2 for the mounting need to be drilled and tapped.

[jaydog82]

Here are some pics of the EGR layout

EGR mount, center drill into EGR passage, side holes drilled and tapped for mounting bolts
http://i469.photobucket.com/albums/rr54/jaydog82celi/exhaustport4.jpg

EGR passage to drill into. Where the pipe plug is on the jdm head is solid and needs to be drilled and tapped, also i am going to drill into the exhaust port from here
http://i469.photobucket.com/albums/rr54/jaydog82celi/exhaustport5.jpg

drill straight through to the exhaust port
http://i469.photobucket.com/albums/rr54/jaydog82celi/exhaustport1.jpg

EGR passage into the exhaust port
http://i469.photobucket.com/albums/rr54/jaydog82celi/exhaustport3.jpg

one of my 2 engines that sit outside, pic of the EGR hole from the exhaust port to the EGR passage
http://i469.photobucket.com/albums/rr54/jaydog82celi/exhaustpor6t.jpg

blank EGR mount on the JDM head
http://i469.photobucket.com/albums/rr54/jaydog82celi/EGR.png

[Doowstados]

This is incredibly helpful, thanks!

I vote sticky in forced induction section!

[jaydog82]

Thanks, i have yet to do this, but it should work out nicely. Ill finish the writ up after i do the drilling and tapping later this week.

[joe's gt]

True, definitely helpful if my local smog shop decides to turn on me and my fake egr on my swap

[jaydog82]

Update time, I got the egr passage from the side of the head into the exhaust port done.

First use a small drill bit to start the hole
http://i469.photobucket.com/albums/rr54/jaydog82celi/IMAG0038.jpg


I used a bag to collect the metal shavings.
http://i469.photobucket.com/albums/rr54/jaydog82celi/IMAG0040.jpg
http://i469.photobucket.com/albums/rr54/jaydog82celi/IMAG0041.jpg
http://i469.photobucket.com/albums/rr54/jaydog82celi/IMAG0042.jpg


Be careful not to brake the drill bit, its a pain in the ass to get it out
http://i469.photobucket.com/albums/rr54/jaydog82celi/IMAG0039.jpg


Be sure to plug up the exhaust port
http://i469.photobucket.com/albums/rr54/jaydog82celi/IMAG0043.jpg
http://i469.photobucket.com/albums/rr54/jaydog82celi/IMAG0045.jpg
http://i469.photobucket.com/albums/rr54/jaydog82celi/IMAG0046.jpg


Drill through into the exhaust
http://i469.photobucket.com/albums/rr54/jaydog82celi/IMAG0047.jpg
http://i469.photobucket.com/albums/rr54/jaydog82celi/IMAG0049.jpg
http://i469.photobucket.com/albums/rr54/jaydog82celi/IMAG0050.jpg


Tap the outer hole for a pipe plug
http://i469.photobucket.com/albums/rr54/jaydog82celi/IMAG0052.jpg

Next up is the top end for the EGR tube
http://i469.photobucket.com/albums/rr54/jaydog82celi/IMAG0051.jpg

[jaydog82]

i finished, but there was a problem. I drilled through the EGR port to the outside, so some aluminum welding will be required.

firist i drilled the egr port from the top down
http://i469.photobucket.com/albums/rr54/jaydog82celi/my%201988%20toyota%20AllTrac/IMAG0126.jpg
then i drilled and tapped the EGR tube mounting.
http://i469.photobucket.com/albums/rr54/jaydog82celi/my%201988%20toyota%20AllTrac/IMAG0125.jpg
http://i469.photobucket.com/albums/rr54/jaydog82celi/my%201988%20toyota%20AllTrac/IMAG0128.jpg
here is the problem hole i created, woops now i need to have it filled
http://i469.photobucket.com/albums/rr54/jaydog82celi/my%201988%20toyota%20AllTrac/IMAG0131.jpg