Air injection pump removal

[darling930]

Hi All. Been a while since I have posted anything here but I have not done much with my car until yesterday. Pulled the engine to replace the clutch in my '87 930. While it is out I was going to do several other things to it. I was wondering if any of you have removed the air injection system? If so what need to be done? I have taken the air injection system off of a '73 MG but that was a much simpler system.
Thanks

[Ken911]

Remove the pump and all the lines. Our sponsor sell the plugs for the heads where the air lines go in. Not too many people here still have that on the car anymore. Probably be able to sell it all to someone in CA for their BS smog inspections

[darling930]

Thanks, that is what i figured but thought better to ask first rather than regret later

[oilonly]

Do some searches here darling, there are plenty of threads on it with pictures and very good instructions.

[mark houghton]

Originally Posted by darling930

Hi All. Been a while since I have posted anything here but I have not done much with my car until yesterday. Pulled the engine to replace the clutch in my '87 930. While it is out I was going to do several other things to it. I was wondering if any of you have removed the air injection system? If so what need to be done? I have taken the air injection system off of a '73 MG but that was a much simpler system.
Thanks

'73 MGB....man, I could swap stories on those - having owned as '73 for 18 years before some soccer mom in her van ran a red light and I T-boned her at 50 mph (she certainly deserved a good boning for that stunt, but the judge probably would have considered that as inappropriate behavior).

Good advice from fellow Pelicanites, and well documented procedures available with a simple search.
With that said I hate to admit it, but my car came with the air injection stuff all removed.....with the exception of the injectors and mainfold plumbing. That $hit is still there (plugged, of course). I haven't looked underneath for awhile but if memory serves me, removing the lower portions of the air injection system requires first removal of the exhaust header/manifold. Again, memory may be flawed here, so I guess this gives me a reason to pull the stock exhaust and slap on an aftermarket header.

[Spenny_b]

I removed the air injector assy not long after buying the car (964T), rotted away on the manifold/branch piping, the injectors were in almost as bad a shape. Pump/bracket/belt all come off, plus some piping that went into the exhaust system. Saves decent amount of weight.

Bought some bungs to plug the injector holes from a 911 parts supplier here in the UK; just before embarking on my EFI conversion, one of the bungs came out (Loctite won't work @ these temps). My plan, had I not taken the plunge on the engine project, was to source some M10x1.0 bolts with hex heads, corner drill the hex and wire-lock them in. The bungs I had bought were the ones with a recessed allen key hex, so not poss to drill for wire locking.

As it happens, as the engine is apart and a lot of head work is being done, the orifices are going to be plugged with threaded ally bungs, then welded in place from the outside, and die ground from the inside to remove any steps and improve the flow (which I'm sure will almost be immeasurable, but satisfies my OCD)

[JFairman]

I removed the whole thing and pugged the air injector holes in the heads wiuth the stainless steel allen head kit pelican sells. They come with copper sealing washers.

I put them in tight as I could with a 3/8" drive socket wrench with red loctite 5 years ago and have not had any problems with them coming loose or blowing out so if you put them in real tight just short of stripping or breaking things they stay.

[Richard930]

This is on my list of things to do before my heat exchangers go on. I've been driving around with the remnants of the air injection pipes and in the late fall the biggest part finally failed and broke off somewhere, so the car got put away for the winter sounding a little "beetleish". Can the air injectors be removed and the plugs fitted with the headers in place, or am I going to need to remove the headers first?

[Ken911]

Originally Posted by JFairman

I removed the whole thing and pugged the air injector holes in the heads with the stainless steel allen head kit pelican sells. They come with copper sealing washers.

I put them in tight as I could with a 3/8" drive socket wrench with red loctite 5 years ago and have not had any problems with them coming loose or blowing out so if you put them in real tight just short of stripping or breaking things they stay.

first set i had red loctite still half of them blew out. that was the weekend at sebring that i also broke all the rings and partially melted a piston. when a hose on the boost controller split. after that I center punched (LIGHTLY) the threads on the plugs screwed them in and they have stayed ever since.

[gsxrken]

Originally Posted by Richard930

This is on my list of things to do before my heat exchangers go on... Can the air injectors be removed and the plugs fitted with the headers in place, or am I going to need to remove the headers first?

What headers do you have that have removable heat exchangers?

I was able to easily get mine out without removing the headers. You can easily see the threaded hole where the fitting was, but I have Brian's headers without heat exchangers.

[Richard930]

I have Brians headers as well. Heat exchangers are with FedEx on their way to me

[gsxrken]

Originally Posted by Richard930

I have Brians headers as well. Heat exchangers are with FedEx on their way to me

You bastard.
Post pics.

[Richard930]

Will do!

[gsxrken]

Originally Posted by Richard930

Will do!

Hey- been off for awhile - did you post any pics or feedback on the heat? Thanks

[Richard930]

I now have them, but the car is in storage so I can't get started on the install yet. Hope to get to it after March break.

[MatteoG]

Resurrecting this thread. I have removed the air injector and now I want to remove the bracket that held the air injector. It looks like there are three bolts that hold it in. But it looks like when I remove the bracket, the bolts need to go back in. And then they are too long. Is it true that bolts are needed to be put back into the engine once the bracket is removed? If yes, do I use the same bolts or do I use shorter ones?
Thanks!