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Freeway Fix story
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Posted by MS (more from MS) on Mon, 17 Dec 2007 23:17:39 Share Post by Email
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To plug one of the unused vacuum holes on top of my intake manifold, I've been using one of those "hole plugs" available in auto stores. They come in a variety of diameters, with the smallest one (3/4" - 7/8") being the size that fits this hole. You slip it in and screw down the nut, which expands the rubber and seals the hole. It's worked perfectly for 2 years. Then yesterday while doing something with the fuses, I noticed that plug was creeping out of the hole. Tugging on it with medium force, I was able to pull it free. No doubt the rubber had shrunk from the heat and pressure over time. So I put it back in and cranked it down some more, thinking I'll have to get a new one sometime soon.

So later that night I had to drive into town to meet someone. It was maybe 45F outside, dark, and a clear freeway for a change. So I motor up the onramp and open up with the psi to reach cruising speed, when all of a sudden I heard "pfoooo," and then no power. With the engine dead I coasted over to the far right shoulder and had to use the E brake to come to a stop. From past experience, I knew it was likely I blew one of the rubber intake tubing seals during that max psi moment. Last time that happened it was an easy fix by reattaching the tubing and "super" retightening the clamp. It couldn't be that manifold plug I just retightened earlier in the day, right? Sure enough, it was that plug. And not only did it pop off, but it was nowhere to be found in the engine bay. Maybe some 200 feet back I'd find it, but that wasn't gonna happen in the dark with only a flashlight while cars flew past me at 60+mph. With nothing else to plug it with, I would have made a plug out of paper towels and electrical tape, and avoided using turbo pressure until I got back home to plug it proper. Instead of that, I was lucky to find in the spare parts box a plastic vacuum fitting and rubber grommet of the exact size needed. With the rubber sealing cap over it's open port. Thank god for my habit of keeping miscellaneous spare parts in the trunk! Popped it in and away I went. That was last night. As of 9 pm tonight, it now has a proper replacement plug.

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