Hi. I've read several EGR delete threads on this and other forums. What exactly should I use to plug the exhaust manifold port? People seem to just come up with random stuff that they make work. Is there something specific I should use? Thanks!

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I use freeze plugs but i typically don't keep cars long enough to know how long a freeze plug lasts. Most folks tap a round plate over the port for the annular clamp to hold in place.

Sixto
98 E320s sedan and wagon

Why plug it? Just cut a little hole in the hood and let it vent out.

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Thanks Sixto. So, a flat plate with the ends bent over, like a bottle cap, and then clamped down. That's air tight and won't make a mess all over the exhaust manifold? Interesting.

So, what would be a good material for this plate/cap?

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NOW: 2017 C43 AMG, 2006 Wrangler Unlimited Rubicon, 1966 230SL, 1980 450SL (for sale!)
PAST: 2006 C230, 1997 E300D, 1994 E420, 1994 Neon Spt Cpe, 1984 300ZX, 1983 Celica GT, 1976 Electra Limited, 1984 Honda Nighthawk 650, 1979 Suzuki PE175, 1978 Suzuki DS100
www.mbca.org - www.sl113.org - www.ohio4x4.com

Whatever mufflers are made of, 50 cent piece, ...

Sixto
98 E320s sedan and wagon

......... yea, like I said.

I'd like to have all the parts ready before I start working on it. So, if a freeze plug is the thing to use, what size? If a plate, what material/thickness?

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NOW: 2017 C43 AMG, 2006 Wrangler Unlimited Rubicon, 1966 230SL, 1980 450SL (for sale!)
PAST: 2006 C230, 1997 E300D, 1994 E420, 1994 Neon Spt Cpe, 1984 300ZX, 1983 Celica GT, 1976 Electra Limited, 1984 Honda Nighthawk 650, 1979 Suzuki PE175, 1978 Suzuki DS100
www.mbca.org - www.sl113.org - www.ohio4x4.com

I used one of these on the 97.


30k miles later.

And if it ever fails I have 3 spares.

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Those devices posted by TJTS1 are located in the electrical aisle of your favorite home center. They are used to close off unused openings in electrical boxes and panels. Slang name for these is "oops plug" or "goof plug".

You will need to fold the tabs in using pliers as seen in his second photo and then secure under the clamp.

TJTS- I think you got a little leak there, I can see the black soot stain at the bolt.

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2014 ML350 Bluetec (wife's DD)
2013 E350 Bluetec (my DD)

both my kids cars went to junkyard in 2023
2008 ML320 CDI (Older son’s DD) fatal transmission failure, water soaked/fried rear SAM, numerous other issues, just too far gone to save (165k miles)
2008 E320 Bluetec (Younger son's DD) injector failed open and diluted oil with diesel, spun main bearings (240k miles)

1998 E300DT sold to TimFreeh
1987 300TD sold to vstech

Yeah I never used any sealant on it. Some of that copper paste would be handy. Either way I've never seen or smelled any smoke out of it. Wish I could say the same about my om603 stock exhaust lol.

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Thanks for the details! I have been told about "electrical blanks" before, but didn't understand. Great pics and explanation. I'll look for copper paste as well.

Love this forum!

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NOW: 2017 C43 AMG, 2006 Wrangler Unlimited Rubicon, 1966 230SL, 1980 450SL (for sale!)
PAST: 2006 C230, 1997 E300D, 1994 E420, 1994 Neon Spt Cpe, 1984 300ZX, 1983 Celica GT, 1976 Electra Limited, 1984 Honda Nighthawk 650, 1979 Suzuki PE175, 1978 Suzuki DS100
www.mbca.org - www.sl113.org - www.ohio4x4.com

I have used a manual transmission drain plug before, the VW style that uses 17 mm allen wrench. It's sized just right to turn it into the hole a few times before it won't go any more. Some loctite red gel on the threads and it's been solid ever since.

On my newest w210, I removed the exhaust manifold and had the local machine shop weld it shut.

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