2.9 Whipple and aftermarket fuel rails w/ EGR

I'm really liking the looks of the Whipples with the new Gen3 rotor pack and I'd like to pick up a 2.9L. I have, however, dug up several old threads that mention there is a problem with keeping the EGR with the 2.9 and aftermarket rails (Fore in this case).

I couldn't find much detail on what that issue is exactly, my best guess is the AN fitting on the back of the passenger side rail is in the way. I found an old post from 2014 by the guys at Lethal Performance that mentioned their solution was to go to a dead head setup, regulator before rails, come into the rails from the front and just plug the back. Not interested in going dead head, not interested in losing the EGR, and not interested in the 3.4 due to the clearance issues (don't want to go aftermarket hood or lower motor mounts).

I gave Whipple a call and they said it's not a problem. Not sure if I believe them since they said they were never aware that it actually was an issue to begin with when it clearly was. I then asked if there had been any updates to the blower in the last few years that would have changed the location of the EGR and they said no. So anyways, can anyone confirm if this is still an issue and if it is, is there any work around other than going dead head or deleting the EGR?

Depending on the fuel rails, some people have had to clearance the EGR slightly. I have 2.9 with aftermarket fuel rails(full return with fuel lines on both ends of the rails) and had to clearance the EGR. Some of older rails, were larger and may have had issues that could not be fixed.

69b302 said:

Depending on the fuel rails, some people have had to clearance the EGR slightly. I have 2.9 with aftermarket fuel rails(full return with fuel lines on both ends of the rails) and had to clearance the EGR. Some of older rails, were larger and may have had issues that could not be fixed.

Click to expand...

I'm running Fore rails that were manufactured within the last 6 months if that matters. Mind sharing what did you do to clearance the EGR, just some grinding on the rail perhaps?

I did not grind anything off my billet rails, but rather took a little off the bottom/side of the cast iron EGR.

I have not upgraded my OEM fuel rails to Fore because of the fitment note on their web-site: "Whipple superchargers (2.9 requires EGR delete)"

I am also interested in how others have made them work...

69b302 said:

I did not grind anything off my billet rails, but rather took a little off the bottom/side of the cast iron EGR.

Click to expand...

SCGallo2 said:

I have not upgraded my OEM fuel rails to Fore because of the fitment note on their web-site: "Whipple superchargers (2.9 requires EGR delete)"

I am also interested in how others have made them work...

Click to expand...

You can go to a dead head setup and come into the rails from the front, although I'd assume most will not want to do that. The other option is to do a bit of grinding.

69b302 - can you snap us a pic? I'd like to see you much you took off.

I've seen folks grind some of the iron on the bottom of the EGR. However most seem to install per Whipple's instructions which leaves a very small gap from the end of the fuel rail to the bottom of the EGR. The concern obviously is the heat transfer from the EGR to the fuel rail.

I have DivisionX fuel rails, but the rest of the fuel system is Fore. Below is a picture of the back end of the passenger fuel rail. I did put some heat cloth around the fitting, due to being close to the hot EGR. I used some low profile fittings to make the job easier. Did not take much grinding.

I just deleted my EGR all together. Much easier then having to worry about fitment.

Sent from my Pixel XL using Tapatalk

c0rn_fed said:

I just deleted my EGR all together. Much easier then having to worry about fitment.

Sent from my Pixel XL using Tapatalk

Click to expand...

Any issues passing emission test?

moncho said:

Any issues passing emission test?

Click to expand...

I haven't got a check engine light for it or had any other issues. So it should pass emissions

Sent from my Pixel XL using Tapatalk

This previous thread states it affects emissions...

Also, provides good info on deleting the EGR.

69b302 said:

I have DivisionX fuel rails, but the rest of the fuel system is Fore. Below is a picture of the back end of the passenger fuel rail. I did put some heat cloth around the fitting, due to being close to the hot EGR. I used some low profile fittings to make the job easier. Did not take much grinding.

View attachment 1475406

Click to expand...

Thanks man, so looks like it can be done. It looks like you have a 180* AN fitting on the back of your rail there and you're routing the fuel line back up towards the front of the blower? My fuel line coming out the back of that rail is running back behind the blower and back towards the driver's side. I might have a few more issues with that as it would have to run under the entire EGR apparatus....hard to tell how much clearance is there from the pic.

Yes, a 180 fitting on the back of both rails. My system is actually fed from the front(converted from deadhead), with return in the back. Not much room behind the blower for multiple large fuel lines, so all lines come to the front then to the drivers side Y block and regulator. NYS has VIP2 inspections, so EGR must be working and all I/M tests must run, so not an option for me to delete.

SCGallo2 said:

I have not upgraded my OEM fuel rails to Fore because of the fitment note on their web-site: "Whipple superchargers (2.9 requires EGR delete)"

I am also interested in how others have made them work...

Click to expand...

Where do you see that on Fore's website SCGallo? Someone mentioned to me that the rails had been re-designed and now work with the 2.9 and EGR. I checked out Fore's website tonight and the only applicable note I see on the rails is - "Same height profile as OEM rail. Fits all known blower configurations." Here's the link:
http://www.foreinnovations.com/product_p/6-900.htm

I'm going to give Fore a call tomorrow and confirm.

RBB said:

Where do you see that on Fore's website SCGallo?

Click to expand...

From the link you provided, click on the “fitment and specifications” tab.

Just delete the EGR

rotor_powerd said:

Just delete the EGR

Click to expand...

That’s the conclusion I’ve come to. My wife and I have been talking about moving to an area where I know I’ll be tested for emissions in the next couple of years, so it would’ve been nice to keep it. I guess I’ll worry about that later and just toss it for now.

make sure to keep your sip sensor intact.