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Removing the AIR and EGR systems

bom ax, 19 January 2003

'01 and '02 Fbodies do not come equipped with EGR. This is a very easy procedure and should take no more than 30 minutes from start to finish. The primary purpose is to clean up the engine bay. Sure, we're removing 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 car. 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. Please note: Removing this system should NOT throw any codes! The following diagram shows the path of the AIR hoses (blue lines). The blue "X" is the location of the AIR pump. The two blue circles are where the AIR hoses connect to the headers or exhaust manifolds. This is the same pump that makes an annoyingly loud whirring noise during startup and sometimes while cruising.

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 bolts for each connection. 2) Next undo the plastic 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 metal 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 located just behind the driver's side headlight in a small cavity. If you peek through you can see it from the top. Jack up the car a bit and you will see there is a plastic shroud covering the cavity. Take your 10mm ratchet and undo 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 work them from the bottom. It should be pretty easy if you use a flashlight to get a clear view of the bolts. 7) Put the plastic shroud 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 with 1/2" holes on either side to bolt up to the holes. You can use the AIR piping you removed as a trace. Here is an example:

9) Put some RTV sealant on them as pictured, then bolt them into place. They only require 18 ft/lbs so don't go nuts. That's it! You have just completely eliminated the AIR system from your car! Now for the EGR system. EGR stands for Exhaust Gas Recirculation and what 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. Removing this system will immediately set an SES light. LS1 Edit or similar can remove this light. The EGR system has been highlighted here:

mhtml:file://C:\Users\Drew Henderson\Documents\2000 Camaro SS\_Air & _EGR.mht

Thursday 5/17/2012

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You will need to either buy or make an EGR block-off plate for the header/manifold (only 1). It will 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 AIR plates. You will also need a 1 3/8" Expansion plug/freeze plug from Pep Boys. They are $3. 1) Begin by unbolting the EGR pump from the passenger side head. If I remember correctly, it uses two 13mm bolts. (someone please email me if incorrect). Unplug the pump at this time as well. 2) Next unbolt the EGR from the top of the intake manifold. It is held on by only one 10mm bolt. 3) Unbolt the EGR pipe from the header/exhaust manifold. It's held on by two 10mm bolts. 4) You can now completely 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 bolts. 6) Take your 1 3/8" freeze plug and undo the nut so it is loose but still threaded on there. Now you should place the plug into the top of the intake manifold as shown.

7) Make sure you have fully inserted the plug into the hole, then tigthen the nut all the way down. You now have a leak free plug! It might not look the best, but you can't beat the price! 8) I taped up the electrical connector for the EGR just to protect it. You are done removing the EGR system! Remember you will get an SES light, but it won't harm performance at all.

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mhtml:file://C:\Users\Drew Henderson\Documents\2000 Camaro SS\_Air & _EGR.mht

Thursday 5/17/2012