EGR adapter or way to install
 

Hi ! Trying to install a remanufactured 1994 DOHC head to 1996 DOHC block/car, everything looks good (the additional coolant temp hole is blocked easy by an extra sensor) . But the EGR seat is way different
https://cimg9.ibsrv.net/gimg/www.sat...f615e9eaeb.jpg
shape of the port on the head (1994)
https://cimg5.ibsrv.net/gimg/www.sat...7f3f1c40e7.jpg
shape of the EGR valve (1996)
. Any suggestion ? Is there an adapter plate ?

94 was the last year of vacuum actuated EGR valve motion.

95 was the first year of electric linear EGR control.

I believe there may have been an adapter plate at one time but I haven't seen one in decades. And I don't know in which direction it was adapting.

If your state does not have emissions testing, cut a piece of metal as in quarter to half inch aluminum plate, drill the side holes, and just block it off. However, if your state does consider a check engine light a failure of a standard part of the inspection, then that won't work for you. Let me go look something up about the plate.

Hi Derf ! California, SMOG check mandatory so the EGR should be there, removing is not an option. Thank you

From the Almighty s series swap guide

91-'94 heads can be adapted to later year engines and use the new style EGR valve if you get the adapter from Saturn that was used on 1994 DOHC cars sold in California, I'l try to dig up the part number at a later time.

He never dug up the part number.
I'll go on a wild goose chase because, well, that's just what I do

Saturn made them for use with California 1994 engines. Something to do with emissions standards.

Most of the junk yards have long since been scavenged for these adapters, with people reselling them on eBay etc. Please see the following post. Apparently it's not even a valid GM part number anymore let alone unavailable. I did not double check. I would use the old part number to search the internet if I were you

https://www.saturnforum.com/forum/ge...-adapter-7725/

in order for the 94s in California to run the linear EGR with only two wires going to the vacuum EGR solenoid, the California PCMS were programmed differently to control the linear EGR valves. So without having both the adapter and a 94 California PCM, nothing will be able to control the actual linear EGR movement.

Wait, I may have read your swap backwards. Please hold

Okay here's the deal.

Chassis engine and PCM are 96 and use linear EGR
So wiring is already present for linear EGR. PCM can already control linear 1996 EGR valve.

Electronic control will not be an issue. The only issue would be a matter of proper flow.
In Theory you would need a thin aluminum block with the shape of one at the inlet and the shape of the other at the outlet plus a matching gasket to seal on each side.

Alternately, you can try either gasket and see if it seals.

People used to machine these back in the day or grab them from junk yards but unless you find one on eBay, you're going to have to keep the gaskets from leaking. It's pretty much raw exhaust so if it's leaking you'll hear it. The car will throw codes for insufficient EGR flow and or the EGR not moving quickly enough to the position the PCM commands it to go to. Considering California's emission standards, I don't think that thing can leak.

Sorry for the cheesy solution, but unless you know some of the more obscure knowledge, it's easy to hose yourself in a swap. Consider your issue minor.

Thanks for ideas. Will try to make the adapter, doesn't look difficult. Ordered a 3/16" x 2" x 12" 6061 aluminum bar. Will CNC it as soon as I get it.
https://cimg0.ibsrv.net/gimg/www.sat...2b911b7e95.jpg

Machinist, eh?