DIY EGR Delete

[RUS Mazda]

NOTE: Pictures will be up later, so far I just have the directions.

I didn't want to pay anything over $10 for a piece of aluminum and a bolt so I've decided to make my own EGR delete kit. Here is a quick guide on how to do it.

Step 1: Disconnect and remove the battery.

Step 2: Remove the TIP

Step 3: Locate and remove the brass pipe that exits the EGR valve. I believe they were 8mm bolts.

Step 4: Remove the gasket that is clipped to the brass pipe and trace it on a piece of metal. My choice of material was a wall outlet backing that I bought for $1.39 at Home Depot.

Step 5: Drill the two holes first and then cut out your gasket copy. I used metal shears but you can also use a grinder.

Step 6: Remover the IC piping going into the throttle body and remover your throttle body. I didn't unhook the electrical connection or the coolant lines, just moved the TB out of the way.

Step 7: Locate and remove the plug holding the other end of the brass pipe. I used an open ended wrench for 7/8, but I would recommend using a crow's foot wrench if you have it.

Step 8: Plug up the hole in the intake manifold. I don't remember the size of this plug off the top of my head because I had it laying around from my previous car's EGR block off.
I'll try to swing by O'reilly and get the size.

Step 9: Attach the gasket onto the block off plate that you cut earlier and put it over the original opening. My plate wasn't the exact size and shape of the original, but as long as its big enough to cover that hole I don't think it will be a problem.

Step 10: Re-install your TB, piping, TIP and battery.

After the block off my boost air temps dropped about 10-15 degrees Fahrenheit during my commute in the middle of the day in Houston.