Hi everyone, I am new to this site. I just bought a 2004 Pacifica with 120,000 miles on it. The engine light was on when I bought it, I ran the codes and the EGR is bad. The guy we bought it from said he was aware of the code and the new EGR was in the back. I thought everything was great untill I went to install it, the bolts going into the engine block are stripped. Does anyone have a suggestion to get me out of this jam. Thanks

 

"the bolts going into the engine block are stripped"

Not sure what you are dealing with but if they are truly bolts and the threads are stripped, you should be able to get them out with pliers. Then drill out the holes and tap them for a larger diameter bolt. Be careful when drilling not to go any deeper than the existing hole. Engine blocks are relatively easy to drill. If the location makes it impossible to drill and tap, find some self tapping screws. If you want to get fancy, get some heli-coils to replace the threads.

If they are studs sticking out of the block and the threads are stripped, again, they should come out with pliers or vise-grips, maybe with some penetrating oil (like PB Blaster) to help, then replace the studs.

You will probably find the bolts or studs you need at the hardware store or local auto parts store. Look up drill/tap sizes on the internet. Everything should be in metric sizes.

 

The bolt heads are stripped, the previous owner must have tried to replace the EGR before he sold it. I cant get nothing to bite on the bolt head, these things are stripped. Both of them. I'm beginning to think the EGR is going to have to be broken off? I am out of ideas.

 

There are sockets available that are made to deal with rounded bolt heads and nuts. Sears sells a couple of Craftsman sets for the purpose (Grip Tite and Bolt Out) and there are other kinds, too (Gator Grip). As a last resort, you might be able to grind the heads square.

 

Real tight area, I have tried the craftsman sockets for stripped bolts and nuts and another brand from sears. Neither worked.Cant get any kind of a grinder in there.

 

Can you get at it with a drill?

 

No. Drivers side of engine behind exhaust pipe. If you remove the battery, it gives you a little more room to work but not much. How hard would it be to break the tabs on the old EGR and attack it that way. It would give me more room to work on the bolts. I am not for sure how hard it would be to break them tabs.

 

Sent to the shop. Hope they can get that EGR valve off. I also got some bad news from the shop today, It needs a timing belt. $475 for labor and I got a discount on the timing kit $151. Wow what a week.

 

With 120,000 miles on it, it's wise to replace the timing belt. Bad things can happen when they break.

 

Now I am getting a P0403 and a P2066 code. I cant find any damaged wires going to the EGR from the harness or from the O2 sensors to the harness. Any ideas or suggestions? Thanks