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From ls1cama=
ro.net
http://www.ls1camaro.net/=
Removing the AIR and EGR systems
bomax,
19 January 2003<=
/p>
'01 and '02 Fbodi=
es do
not come equipped with EGR.
This is a very easy
procedure and should take no more than 30 minutes from start to finis=
h.
The primary purpose is to clean up the engine bay. Sure, we're removi=
ng
about 15lbs of crap, but that is almost negligable. Also by removing =
the
AIR pump you can eliminate the annoying whine when you start up the c=
ar.
First we'll start=
with
the AIR system. AIR stands for=
Air
Injection Reaction, and it is a system designed to reduce emissions on
cold start ups. It injects fresh air directly into the exhaust stream=
which
helps the catalytic converters before they are fully warmed up. If you
have eliminated cats then this system is totally useless to you. P=
lease
note: Removing this system should NOT throw any codes! The follow=
ing
diagram shows the path of the AIR hoses (blue lines). The blue
"X" is the location of the AIR pump. The two blue circles a=
re
where the AIR hoses connect to the headers or exhaust manifolds. This=
is
the same pump that makes an annoyingly loud whirring noise during sta=
rtup
and sometimes while cruising.
![](3D"RemovingAIRandEGRSystems_files/image001.jpg")
1) Begin by using a
1/4" drive 10mm socket with an extension and disconnect the AIR
hoses from the headers/manifolds. (The blue circles). There are two b=
olts
for each connection.
2) Next undo the pla=
stic
connections holding the rubber AIR tubes on to the metal AIR pipes.
(About where the Strut Tower Brace is located). The plastic clamps are
located just behind the bulges in the pipes.
3) Now remove both m=
etal AIR
pipes.
4) Snake the rubber =
tubes
through the back of the engine bay (following the blue path) to remove
them. You will be able to get it out until you reach the pump itself =
(the
blue "X").
5) The pump is locat=
ed just
behind the driver's side headlight in a small cavity. If you peek thr=
ough
you can see it from the top. Jack up the car a bit and you will see t=
here
is a plastic shroud covering the cavity. Take your 10mm ratchet and u=
ndo
the bolts holding this plastic piece on. On my car there were also a =
few
8mm bolts for some reason.
6) Once the plastic =
shroud
is off you can clearly see the AIR pump. There are four bolts holding=
the
pump on. You will need to get a long extension on your ratchet and wo=
rk
them from the bottom. It should be pretty easy if you use a flashligh=
t to
get a clear view of the bolts.
7) Put the plastic s=
hroud
back on, and lower the car down.
8) Now you are ready=
to put
the block-off plates on the headers/manifolds. You DID make some
block-off plates, didn't you? If not just grab some RTV sealant, some=
tin
snips, and some 22ga cold rolled steel. Cut out two pieces of metal w=
ith
1/2" holes on either side to bolt up to the holes. You can use t=
he
AIR piping you removed as a trace. Here is an example:
![](3D"RemovingAIRandEGRSystems_files/image002.jpg")
9) Put some RTV seal=
ant on
them as pictured, then bolt them into plac=
e.
They only require 18 ft/lbs so don't go nuts.
That's it! You ha=
ve just
completely eliminated the AIR system from your car!
Now for the EGR s=
ystem. EGR stands for Exhaust Gas Recirculation and w=
hat it
does is take exhaust gas from your header/exhaust manifold and inject=
it
right back into your intake to be re-burnt. This is supposed to help
reduce emissions. The '01 and '02 cars do not have this system. Remov=
ing
this system will immediately set an SES light. LS1 Edit or similar can
remove this light. The EGR system has been highlighted here:
![](3D"RemovingAIRandEGRSystems_files/image003.jpg")
You will need to eit=
her buy
or make an EGR block-off plate for the header/manifold (only 1). It w=
ill
need to be slightly larger than the AIR plates. You can use the EGR
connector as a trace (for the header/manifold) like you did for the A=
IR
plates. You will also need a 1 3/8" Expansion plug/freeze plug f=
rom
Pep Boys. They are $3.
1) Begin by unboltin=
g the
EGR pump from the passenger side head. If I remember correctly, it us=
es
two 13mm bolts. (someone please email me if
incorrect). Unplug the pump at this time as well.
2) Next unbolt the E=
GR from
the top of the intake manifold. It is held on by only one 10mm bolt. =
3) Unbolt the EGR pi=
pe from
the header/exhaust manifold. It's held on by two 10mm bolts.
4) You can now compl=
etely
remove the EGR pump and tubing from the car.
5) Now put some RTV =
gasket
maker on the EGR cover you made or bought, and place it on the
header/manifold. Torque it down to 18 ft/lb reusing the two 10mm bolt=
s.
6) Take your 1 3/8&q=
uot;
freeze plug and undo the nut so it is loose but still threaded on the=
re.
Now you should place the plug into the top of the intake manifold as
shown.
![](3D"RemovingAIRandEGRSystems_files/image004.jpg")
7) Make sure you hav=
e fully
inserted the plug into the hole, then tigthen the nut all the way dow=
n.
You now have a leak free plug! It might not look the best, but you ca=
n't
beat the price!
8) I taped up the el=
ectrical
connector for the EGR just to protect it.
You are done remo=
ving the
EGR system! Remember you will get an SES light, but it won't harm per=
formance
at all.
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