slownrusty

Well gang here is the final installment of emissions and the air injection removal on my 930, thought I would share:

Here is the air injection manifold before removal:



Here is the manifold removed and starting to remove the actual air injectors. Removal is VERY straightforward and simple. Took me about 10minutes and I was very careful too make sure if I felt any the threads starting to strip \ stretch - luckily none - but you can never be too careful!


To seal the holes in the heads where the air injectors used to live, I bought six Fine thread 1.00 Allen head hardened bolts and cut them down with my trusty Dremel (life saver) to a length that made them just a tad shorter than the depth of the hole in the head. I also used a new lock washers and Permatex Graphite Anti-Seize on the threads as well. The Allen head bolts and the lock washers cost me $4.00 from Ace Harware and it took about 10minutes to do everything and have it installed - EASY! The lock washers have to a diameter such that they do not bind on the head and seat on the flat section where the old air injectors used to be (only note to self). Looms so much neater too under the car and loose some weight too.
Stock air injector next to the new Allen Bolt:


After surgery:


Ready for installation:


Installed:




Good reference for anyone wanting to do this in the future. The best part is I have all the OE emisions stuff in a boz and can retro-fit it to the car if need be.

Regards - Yasin

Sameer

Thanks Yasin, will be printing this out to have it done.

Kevin

One further suggestion is to trial fit the allens and torque them down. Scribe the angles of where the fastner protrudes into the exhaust port, remove and grind to the angled profile. This allows the exhaust to flow smoothly out the port.

Sameer

Ok Kevin

slownrusty

You have to be very careful cutting those Allens at an angle as Kevin suggested, they are 1.00 FINE pitch thread and if you cut them at an angle like say 45degrees to match the exhaust port hole, you will have a bear of a time getting them to thread into the head EVEN if you use a thread chaser.

I cut mine so that they lie just below the exhaust port and do not protrude into the port like the old air injectors.

Just a heads up.

Yasin

SoFast

Yasin is correct.....It would be very, very difficult. The flow is not being inturded upon by the allens sticking out into the port, so leaving them lie just below is your best bet.

Sameer

Yasin,
I'm at the Ace Hardware website and want to buy the bolts but cant seem to find them. Can you help me here?

Sameer

Yasin,
what is the part number for the bolts?

slownrusty

Not sure the part number on the bolt from Ace. They are Allen Cap Head M8x1.00 (fine thread pitch), I just got them out of a bin in their Fasteners aisle (took about 40minutes) before I found the right one.

The problem here is that the 1.00 fine pitch is not very common. I prefer the Allen head over a regular hex head, as they are smaller head diameter and there is not alot of seating surface on the 930 head where the old air injectors sit.

Try doing a search in Google. Based on "Metric Fasteners" -or- " Allen Head M8x1.00" or any similar combination.

Each Ace hardware probably carries different stock, so their online sites will probably be of no help.

I'll tell you what, if you really have zero luck, I will buy you a set and drop them in the mail to you?

Hope that helps - Yasin

SoFast

Sameer, you can get a good alloy Allen at any Hardware shop. They are pretty easy to find. Just make sure you use the corecct coding on the allen. As well, instead of cutting the allens down, you can buy shorter Allens and save yourself the work.

Sameer

Okie dokie guys, will check it out.

BrianKeithSmith

www.mcmastercarr.com - search for it there.

Sameer

Brian,
Clicked on the link but "The page cannot be found"

WERK-I

Sameer,
Try this;
http://www.mcmaster.com/

Kevin

If I can get 10 people interested, I will make them on my CNC.. Yes, they will be tapered correctly to fit the port.. Crush washers can be used to get the correct clocking! Being that I will cut the threads last and create a shoulder, the threads stripping won't be an issue.