Ok well I got everything in finally. My problems are that the EGR fitting on the driverside header doesn't fit, it hooks up where it needs too but the fitting is too large for the pipe and simply won't screw in. Passengerside EGR fitting was perfect.

Question #1 What size is the EGR (diameter) that connects to the header? I'm going to have to go to a plumming store and find a female to male adapter.

Also I've only put roughly 10 miles on the car so far, and there is a definate loss of power (I'm assuming from KR) and lots of backfiring. I know it should take the computer about 100 miles to figure out the headers but should I be expecting THIS much backfiring? The car recently had a tuneup.

Question #2 Is the backfiring normal? Will it go away after 100 miles?

 

Ok I figured out what the backfire was, a wire that I must have missed melted and is arching onto the header. Got a new set of wires and about to install. But does anyone have the fitting size for the egr?

 

Its actually the AIR pipe you're talking about. I can't remember the size but I got a hydraulic fitting for mine.

 

Are you saying that the AIR tube sticks up too far and the AIR fitting won't tighten down and seal or that the AIR fitting won't even thread onto the driver's side header? On my Pacesetter's the AIR tubes are threaded all the way to the top where the stock manifold aren't. I got some thick washers and used them as spacers and they work great.

 

size is 5/8 I believe but don't quote me on that

 

My AIR fittings were 7/8" fine thread, 18 or something close to that. Couldn't find any in town, so I just cut the pipes off the stock ones and welded them over. Work great.

 

Diameter of the AIR fitting varies with the year. The single cat cars are mostly 22mm (~7/8), and the dual cat-cars are mostly 18mm (~5/8). There are some 95 single-cat cars that have been reported with the smaller fittings. Each header manufacturer seems to pick whatever he wants, including some who reverse the female connection to a male connection.

 

Well here is what I have come up with as a prossible explanation. The motor in the car is out of a 96 Z28, I bought the headers for a 95 because the car is a 95 (figured the dual cat design was a possible reason for the different style headers). I didn't know that there was a difference in the size of the fitting between the years so this must be the reason.

Now I've been to pretty much every auto parts store in my area and I cannot find this fitting ANYWHERE. I even tried home depot, but the fitting isn't a standard plumming size, it's slightly bigger then a 1/2 inch.

Would the chevy dealership have this part?