Due to dificulties with a stuck bolt, one of my AIR pieces will not going to come off the manifold, its just rounding the bolt. I need to keep EGR, but i think im just guna say goodbye to the AIR system. What type of bolt will i need to plug up the AIR ports on the headers? Also what would i need else to plug up the cold air intake. And is there other things i will have to plug or just those 3. And just for clarification, deleting AIR will not make me fail the sniffer test as long as my catalytic converter is hot, correct?

 

I just posted something like this. The AIR removal from the intake manifold is going to take a 5/8" vacuum cap. Injuneer told me that people use the M22-1.5 drain plug to cap the AIR tubes on the headers. I'm not sure what size vacuum cap to use on the CAI. I was also told that it could me an M18. Can anyone help with with the size of Jet Hot LT's?

 

just go to like the plumbing or piping section in home depot and i think it was a 1/2" or w/e i forgot and it fit perfect in it!

 

2 97 Cummings Disel Dodge Ram oil drain plugs

 

Something that might be easier... when you remove the AIR, take the metal piece from each side and have them welded shut... the metal piece that is hollow and not capped, but threads onto the header/manifold. It was much easier for me to do that than trying to find a bolt to fit in there.

 

on the cai air tube, i epoxied a freeze plug on it, works pretty good. I guess the vacuum cap would be easier but i couldn't find one that huge in my autopart stores :P

 

I went to a dodge dealer, they didn't have the drain bolt so i went to a little auto parts store next door and they had it right near the "HELP!" section. Tip: if you try a dealer, don't mention what your going to use it for, you'll get some strange looks. I used a M22x1.5 bolt like was posted and 2 m22 copper washers. The washers weren't necessary though as i couldn't get the bolt down far enough in order for the head of the bolt to go against the header.

http://3gc.net/misc/header-plugged.jpg
Here's a piture of it plugged before i got a chance to remove the smog pump. Getting the actual air fittings off the headers with it in the car still was the hardest part of this small job.

 

I had a similar problem with the passenger manifold. I ended up soaking the AIR fitting with PB Blaster for 3 days and I finally busted it free with a long open end wrench. Just a thought.

 

is there a difference in 97 pacesetter LT headers? Mine has the threads for the air on the outside...?

 

My Jet Hot's had the threads on the outside... just use the metal pieces that thread on there and have them welded up. Best way to do it IMO.

 

On my 97
http://www.ls1camaro.net/freehosting/Left.JPG

You will need to go to a hardware store and get a 1/2" cap.

Make sure you get one that looks like this(Flare Cap)

http://images.orgill.com/200x200/6199434.JPG

I tried the ones that look like these at first, but they will not fit.
Dont get these.

http://doityourself.com/ori/200x200/6102248.jpg

 

93's used M18 94+ will use a M22 the air pump system was different in 93.

 

That's what I used on my SLP Shorties when I removed the AIR. Worked great!

 

Do you have a part number?

 

Dude....that is exactly what I did on my MAC headers for the 97 TA!!! The black cap is too coarse of a thread. The 1/2" copper cap found in Home Depot's plumbing section where they have elbows, reducers, etc, fit perfectly. Good post!